DRS PDF

00 General Information/
Scheduled Maintenance
01 Power Unit
02 Power Transmission
Maintenance
Manual
03 Hydraulic System
UDRS01.01GB 04 Electric System

DRS 4527-4531
05 Cabin
06 Working Devices
07 Frame and Shields
08 Equipment
General Information/Scheduled Maintenance 1
00 General Information/Scheduled Maintenace

00.1 General Information .......................................................................... 3
00.1.1 About the Documentation ....................................................... 3
00.1.2 Warranty Agreement ............................................................... 3
00.1.3 To the Maintenance Personnel ............................................... 4
00.2 Instructions for Initiating into Maintenance Work ......................... 5

00.2.1 General Instructions ............................................................... 5
00.2.2 Maintenance and Repair Personnel ....................................... 5
00.3 Regulations for Safe Maintenance Work ........................................ 6

00.3.1 General Safety View Points .................................................... 6
00.3.2 Concerning the Maintenance and Repair Personnel .............. 7
00.3.3 Preparing for Hazardous Situations ........................................ 8
00.4 Preparing of the Machine for Maintenance ..................................... 9

00.4.1 Maintenance Enviroment ........................................................ 9
00.5 Maintenance Reports ...................................................................... 10
00.6 Lubrication Oil Recommendations ................................................ 11
00.7 Running-In ....................................................................................... 13

00.7.1 Initial Maintenance ................................................................ 14
00.8 Scheduled Maintenance ................................................................. 15

00.8.1 Scheduled Maintenance for Engine Scania DI12 ................. 15
00.9 Scheduled Maintenance ................................................................. 16

00.9.1 Scheduled Mainteanance for Engine Cummins QSM11 ...... 16
00.9.2 Scheduled Maintenance for Gear Box and Power Unit ....... 17
00.9.3 Scheduled Maintenance for Steering ................................... 17
00.9.4 Scheduled Maintenance for Hydraulics ............................... 17
00.9.5 Scheduled Maintenance for Boom ........................................ 18
00.9.6 Scheduled Maintenance for Spreader .................................. 18
00.9.7 Scheduled Maintenance for Others ...................................... 19
00.9.8 Unit Conversation ................................................................. 20
00.9.9 General Tightening Torques ................................................. 24
Maintenance Manual DRS 4527-4531 UDRS01.01GB

2 General Information/Scheduled Maintenance
UDRS01.01GB Maintenance Manual DRS 4527-4531

00.1 General Information

The maintenance manual contains the actual information
required during maintenance work. This information ac-
quaints the maintenance and repair personnel with cor-
rect and safe methods of maintenance and repair work.
The professional support of our maintenance organiza-

tion and the maintenance instructions make possible the
safe, reliable and efficient operation for the machine dur-
ing its operation life.
00.1.1 About the Documentation

The following documentation is supplied with the ma-
chine:
• Operator's manual DRS 4527-4531 (in cab with

machine)
• Maintenance manual DRS 4527-4531
• Spare parts catalogue with machine card
All documentation can be ordered from Kalmar Indus-

tries.
00.1.1.1 Ordering of documentation

Documenation is ordered from Kalmar Industries:
Kalmar Industries AB, SE-341 81 Ljungby, Sweden.
Always indicate publication number when ordering.
00.1.2 Warranty Agreement
Warning!
Negligence of scheduled maintenace measures men-
tioned in this manual will release Kalmar Industries
from all warranty liabilities. Warranty information is
at the end of this manual.

00.1.3 To the Maintenance Personnel

Carefully familiarize yourself with the planned mainte-
nance program, maintenance points and instructions and
follow them during your maintenance work, to secure the
high level of the safety in operation and reliability. Use
oils, greases and liquids, defined later in this manual.
Only original Kalmar parts shall be used. A strict compli-
ance with cleanness especially by maintenance of hy-
draulic and fuel devices by scheduled maintenance is the
best way to be ensure, that the machine operates as
planned. Take care according the instructions on your
working place for the oils, greases and liquids, changed
during the maintenance.
Warning!
Never pour oils, greases and liquids changed during
the maintenance down the drain or in to the earth!
Bear the responsibility for the environment! Only
trained personnel is allowed to maintain the machine.
Do not maintain the machine, if you are not sure about the
safety instructions and orders. Ask if needed for guidance
of safety maintenance in your working place the person-
nel responsible for occupational instruction and guidance
or get in contact with the service organization of the man-
ufacturer.

00.2 Instructions for Initiating into

Maintenance Work
The service and repair personnel must be clear about the
machine operation, the working principles, and the de-
signed functions of the machine systems. The service
section is meant as an introduction to enable correct and
safe service and repair work. Therefore it is important that
the instructions in the manual are studied carefully prior
to work.
00.2.1 General Instructions

To the commissioning of a new machine and the first
scheduled services should be paid a special attention.
The manufacturer has drawn up a special service sched-
ule particularly for this machine. The manufacturer has
contributed significantly to develop a service program to
maintain the proper safety level of the machine. Data for
correct maintenace measures have been collected as re-
sult of an extensive research work. In addition to this,
feedback from different operating conditions has been
considererd very carefully.
By careful following of the maintenance schedule speci-

fied by the manufacturer, a rational and economic main-
tenance of the machine is enabled. The manufacturer has
invested in the profitable training maintenances of a high
level performance. Qualified and experienced trainers
are always available, if problems arise at the client.
00.2.2 Maintenance and Repair Personnel

The machine may be serviced and repaired by qualified
and trained personnel only. The employer is responsible
for selecting of the person suited to the service and repair
duties. The employer is responsible for training of the
service and repair personnel into the proper workmanship
considering the safety at work.
The service person refers to a person, who performs the

scheduled services and eventual repairs at the machine.
The service person must attend to maintain his qualifica-
tions, e.g. by periodically repeated training. The employer
is responsible for maintaining of the qualifications of the
service and repair personnel. The machine must not be
serviced or repaired by personnel who has lost skills. If
necessary, the employer must retrain the person selected
for the service and repair work at the machine.

00.3 Regulations for Safe Maintenance

Work
The person performing the service shall be physically
suited for this kind of work. As far as health and power of
seeing are concerned, the person shall fulfil the require-
ments necessary for the work. The employer is responsi-
ble for selecting the person suited for the duty as well as
for initiating into the correct and safe service work at the
machine.
00.3.1 General Safety View Points

The service and repair personnel of the Reach Stacker is
responsible for that the machine doesn't cause damage
to other persons in connection with the service or repair
work.
1. Thoroughly acquaint yourself with the machiner's

structure and the manuals. Observe the instructions
and warnings.
2. Try to determine the hazards, and avoid them. Report
any faults that you have noticed to your superior or to
the person in charge of repairs.
3. Wear required protective clothing.
4. Always observe sufficient caution and care when
climbing into or coming down from the machine. Al-
ways move along the paths designated as walkways.
Keep the walkways clean. Remove all safety risks,
such as snow and ice, and other foreign matter. Wipe
away all oil leakages at once to prevent slipping.
5. Keep the machine clean, especially the adjusting and
control devices.
6. Do not allow any unauthorized persons to operate the
machine entrusted in your use. The operator of the
machine is responsible for any damage caused by the
machine.
7. Acquaint yourself in advance with the use of emergen-
cy exits.
8. Do not stand under a hanging container or load.
9. If problems arise, remember to stay calm. Think first,
and then act accordingly.

00.3.2 Concerning the Maintenance and Repair

Personnel
1. Before starting off, make sure that nobody is standing
in front or behind the machine.
2. Avoid sudden stops and starts.
3. Always perform the maintenance and repair work ac-
cording to the instructions given.
4. By observing a danger spot, immediately report to the
person responsible for safety.
5. The machine must not be handed over for operation,
until the observed faults and damages have been re-
paired.
6. Observe the signs and instructions indicating free
height. You should know the exact total height of your
machine before driving into places with rstriced free
height. Be especiallycareful with temporary structures,
hanging overhead power lines, etc.
7. You may perform the service and repair work only in
compliance with your actual qualification.
8. Don't try to guess! Maybe you make a wrong guess,
causing a possible danger to yourself and the other
personnel.
9. If necessary, consult a person being aware of how to
proceed.
10.When servicing pressurised systems, proceed very
carefully. Non-discharged energy sources always are
hazardous.
11.Follow unconditionally the instructions given.
12.If it is necessary to remove protective guards during
the service, place warning signs and take other meas-
ures to protect other persons from danger.
13.When changing driving direction, stop the machine
completely with the service brake before moving the
direction selector lever.
14.Watch out for the edges of driveways where the sur-
face may be yelding and cause the danger of overturn-
ing.
15.Remember that the machine is not intended for carry-
ing persons.
16.Always stop the engines whenever you leave the ma-
chine even for a short while. Lower any load to the
ground.

17.Always remember to engage the parking brake before

leaving the cabin.
18.Make a detailed report on any collisions, including the
damage caused. This could prevent accidents from
being repeated.
19.Observe the weight of your carrier, and its total weight
loaded. Do not drive on surfaces with insufficient load
capacity.
20.Follow the periodic maintenance schedule. This en-
sures that the controls and the whole carrier operate
reliably and safely.
21.The engine must always be stopped when service or
inspections are being carried out.
22.The use of open flame is absolutely forbidden when
checking fuel or battery electrolyte levels.
23.The radiator is pressurized when the coolant is hot -
open the radiator cap slowly and cautiously.
24.Do not open the main switch when the engines are
running.
25.Only a person that is well acquainted with the carrier's
control and the cabin equipment is allowed to be in the
cabin during service and repairs.
26.Driving is forbidden without fastened seatbelts.
27.Never park the machine on a inclined plane.
00.3.3 Preparing for Hazardous Situations
00.3.3.1 Maintenance Reports

Inform your superior or the person responsible for repairs
of faults observed at the service. The machine must not
be operated until the faults and damages have been re-
paired.
See to it that your service reports are perfectly recorded.

Record the objects to be repaired individually, and note
the repair measures precisely. In addition to this, try to
find out, why the object has been damaged.
00.3.3.2 Tools
Use only proper tools at the service and repair work.

00.3.3.3 Reporting of Dangers

Always inform in writing your superior or the person re-
sponsible for safety of dangers observed in the service
environment or in machines serviced.
The reports recorded must be filed carefully. It is essential

that the reports are available to be analyzed if necessary.
00.4 Preparing of the Machine for

Maintenance
The service and repair work should be performed in the
premises intended for this use. State the extent of the
service work. Prepare yourself for the service or repair
work by reading the service and repair manuals. Prepare
yourself for the work by tools and materials needed. See
to it that the tools to be used are proper and in good con-
dition. See to it that the warning signs for eventual haz-
ardous situations have been placed in position.
Prior to the service work: Check the reparations made in

the operation of the machine since the last service. Check
the previous service report. Try to find out the expected
safety level on the basis of the information collected;
which points shall be particularly considered at the next
service.
00.4.1 Maintenance Enviroment

1. Provide for placing the service environment to premis-
es, where the machines can be serviced safely and
without exposing the regular work to danger.
2. See to it that the environment cannot be contaminated
by the machine being serviced.
3. Always keep the service environment clean and trim.
4. See to it that there is no danger in the service environ-
ment, which possibly could endanger the personnel.
5. Be aware of the correct action in case of possible ac-
cidents. Keep yourself informed about the location of
the electrical main switches of the service environ-
ment, as well as of the fire extinguishing equipment.
6. Keep yourself informed about the safety regulations
regarding the service environment.

00.5 Maintenance Reports

When performing the service, report the work systemati-
cally in accordance with the service schedule drawn up
by the manufacturer. Note carefully damages observed
and repair measures. The service schedule drawn up by
the manufacturer is presented in section 'First service
and scheduled service' of this main group.
Define and record the safety level of the machine in the

service report after every service. If, by your estimation,
the machine doesn't correspond to the designed safety
level, inform of this your superior responsible for the safe-
ty. After every service, file the service reports.

00.6 Lubrication Oil Recommendations
Required oils, greases and fluids
Class
Filling
Item Type API/ASTM/
capacity / l
SAE
Engine Cummins QSM11 Diesel motor oil API CH4 36
All Seasons, but not Artic condi- SAE 15W-40 or ACEA
tions E5
Engine Diesel motor oil API CE or 33
Scania DSI 12 CF
<-40 ... +30°C SAE 5W-30 CCMC-D5
-25 ... +30°C SAE 10W-30 ACEA E3
-20 ... +45°C > SAE 15W-40
-15 ... +30°C SAE 20W-30
-10 ... +30°C SAE 30
-5 ... +45°C > SAE 40
0 ... +45°C > SAE 50
Hydraulic oil tank Hydraulic oil 1) 600
Cabin transfer hydraulic 2,8
-30+25°C
NESTE MJ 46,
-10+35°C
BP Tracton 9, TEXACO TDH
-10+35°C
Esso Torque Fluid 62
-20+30°C
ISO-VG 46
0+30°C
ISO 68
+10+50°C
ISO-100
Drive axle PRC7534
Rockwell
Differential 60
Planetary gear 2X12,5
-40°C...> Hypoid oil SAE 75W/90 EP GL-5
-26°C...> Hypoid oil SAE 80W/90 EP -"-
-12°C...> Hypoid oil SAE 85W/140 EP -"-
Gearbox Transmission oil SAE 5W30
Clark 36000 UTTO transmission oil 4)
-25 ... +45°C
Rotation transmission Hypoid oil SAE 80W/90 EP GL-5 5,5
Lubricating points of EP Multi-purpose grease NLGI 2
chassis and lifting device example ESSO Unirex EP 2
Lubricating slide planes of boom EP Multi-purpose grease NLGI 2
and spreader example ESSO Unirex EP 2
ore ESSO Moly Grease 2
Central lubrication, EP Multi-purpose grease, Class NLGI 2 2kg
optional 2) example ESSO Unirex EP 2
If the temperature is continuously under NLGI 0
-10×C, EP Multi-purpose grease
example ESSO Unirex EP 0
Fuel tank High-quality diesel fuel 500
Cooling system3) Glycol 50% / water 50% 60
Windscreen washer Windscreen washer liquid 10

Required oils, greases and fluids
Class
Filling
Item Type API/ASTM/
capacity / l
SAE
1. In colder weather, a hydraulic oil heater should be used.
2. Refer to the 'Central oiler' section 08 of the manual.
3. Add DCA4 additive to coolant for Cummins engine, 1,2 units / US gallon. Check the amount of additive with the
test serie CC-2602.
4. UTTO-transmission lubricant must be qualified by on of the following specifications in order of preferance:
Caterpillar TO-4
John Deere J20 C, D
Allison C-4
Dexron oils must not be used.

00.7 Running-In
Long life of the machine can be ensured bu avoiding
great loads and high engine speeds during the first 300
operating hours. During this time, all finely machined sur-
faces reach their final smoothness and hardness.
The engine should not, however be lugged at low speeds

or allowed to idle long.
Especially observe during the running-in period that the

engine and transmission oil pressures and temperatures
are normal. Oil change during running-in should also be
done sooner than normally. Also refer to the engine's
manual for running-in instructions.
During running-in you should also pay special attention to

the tightness of screws and nuts, and tighten them as
necessary.
Running-in of an overhauled engine follows the same

principles as above, but the running-in period is some-
what shorter.

00.7.1 Initial Maintenance

Special attention should be paid to taking a new vehicle
into operation and to its first maintenaces. Maintenance
charges are small compared with cost of repairs caused
by neglect.
Warning!
In addition the proceeding stated in this maintenance
volume a new machine must be subjected to all the
maintenance and checks mentioned in the book.
In addition to the instructions in the maintenance chart,

the following service should be carried out during the first
50...150 hours.
Maintenance of a new machine during first 150 hours
Maintenance itemUDRS01.01GB Interval/working hours
50 100 150
1. Replace hydraulic system filters X
2. Change engine oil X
3 Replace engine oil filter X
4. Change transmission oil X
5. Replace transmission filter X
6. Change differential and planetary gear oil X
7. Change brake oil X
Warning!
Please consult also the engine instruction manual for
running-in directions. Apply these directions after re-
placements of major components, too.
After the initial maintenace do follow scheduled mainte-

nance program, where service intervals are based upon
operating hours.

00.8 Scheduled Maintenance

In the scheduled maintenance of the reach stacker the
maintenance instructions of this groupshall be followed,
though the instructions in the maintenance of the compo-
nents may differ from them.
00.8.1 Scheduled Maintenance for Engine

Scania DI12
Interval in operating hours 6000 h

or at
At least
Maintenance item least
Dai- every
400 1000 2500 every
ly fifth
ENGINE, see also engine manual h h h two
years
years
1. Check the engine oil level x
2. Check the coolant level x
3. Clean the air pre-filter and replace the air filter when x
the clogging indicators show fully red
4. Check cooling fan x
5. Check the possible oil- and the fuel leakages x
6. Clean water separator, if needed x
7. Change engine lubricating oil x x
8. Cleaning oil cleaner x x
9. Replace engine oil filter x x
10. Clean the air pre-filter x
11. Check engine intake system x

12. Checking electrolyte level in batteries, if needed x x
add only battery water
13. Check state of charge and cleanliness in batteries x
14. Check engine screws and tighten to spec. torque x
15. Check hoses and replace if necessary x
16. Replace the air filter and clean the air pre-filter, also x x
when the clogging indicators show fully red
17. Replace engine fuel filter x x
18. Clean and replace the fuel pre-filter (optional) x x
19. Check the condition and tightness of the fan belt x x
20. Clean crankcase breather x
21. Wash up engine x
22. Checking/adjusting valve clearances x
23. Checking/adjusting injectors DI12 x x
24. Checking/adjusting PDE injector rocker arms x x
DI12 PDE
25. Cleaning cooling system and changing cooland fluid x x

00.9 Scheduled Maintenance

In the scheduled maintenance of the reach stacker the
maintenance instructions of this group shall be followed,
though the instructions in the maintenance of the compo-
nents may differ from them.
00.9.1 Scheduled Mainteanance for Engine

Cummins QSM11
Maintenance item Interval in operating hours 6000 h or at

least every two
Dai-ly 250 h 500 h 1500 h years
1.Check the engine belt x
2.Check the engine oil level x
3.Check coolant level x
4.Check cooling fan x
5.Clean water separator x
6.Check air cleaner service indicator; replace filter if indicator x
shows red
7.Change engine oil *) x
8.Replace engine oil filter *) x

9.Replace engine fuel filter x
10.Check additive content of coolant (SCA) x
11.Replace coolant filter x
12.Check engine intake system x
13.Check crankcase breather x
14.Check engine wiring harness x
15.Adjust valves and atomizer x
16.Clean crankcase breather x
17.Steam wash engine x
18.Check turbocharger nuts and tighten to spec. torque x
19.Check engine screws and tighten to spec. torque x
20.Check hoses and replace as necessary x
21.Check state of charge and cleanliness in batteries x
22.Service exhaust catalysis CRT**) (optional) x
23.Flush cooling system and Change coolant x
24.Clean and adjust electronic controlled fuel system ***) x
25.Check water pump x
26.Check fan hub x
27.Check turbocharger x
28.Check idley pulley mouting x
29.Check vibration damper x
*) Change interval 125 operating hours, if engine lubricating oil does not comply with API CF-4 specific.
**) See instructions: CRT-service manual, part C appendixes
***) Adjust requires special equipment and must be done a Cummins Authorized Repair Location

00.9.2 Scheduled Maintenance for Gear Box

and Power Unit
Maintenance item Interval in operating hours At least

250 500 1000 2000 once a
Transmission Dai-ly year
h h h h
1.Check transmission oil level x
2.Check possible oil leaks x
3.Replace transmission oil filters x
4.Change transmission oil x
5.Clean screen filter x
6.Check transmission oil pressure x
Drive Axle
1.Check oil level in differential and planetary gear (common oil x
space)
2.Adjust parking brake according to instructions x
3.Check and tighten screw connections x
4.Check and tighten wheel nuts x
5.Check tyre pressure x
6.Change differential and planetary gear oil x
7.Check parking brake friction surfaces for wear, replace as neces- x
sary (wet disk brakes on drive axle needs no maintenance)
6.Change brake oil x x
00.9.3 Scheduled Maintenance for Steering

250 500 1000 2000 once a
Steering Axle Dai-ly year
h h h h
1.Check steering lingake joints x
2.Check and tighten wheel nuts x
3.Check tyre pressure x
4.Check and tighten screw connections x
5.Lubricate wheel bearings x
00.9.4 Scheduled Maintenance for Hydraulics
Maintenance item Interval in operating hours At

least
250 500 1000 2000 4000 once a
HYDRAULICS Dai-ly
h h h h h year
1.Check hydraulic hoses and connections for possible leaks x
2.Check hydraulic oil level. Sight glass attached to hydraulic x
tank is used for checking. Oil level should be in the midway of
the gauge when spreader is lowered to its standard position and
boom telescopic extension is fully retracted.

3.Replace brake hydraulics filter x

4.Replace hydraulic oil filter x
5.Replace filter element of hydraulic system breather x
6.Measure hydraulic system pressure x x
7.Change hydraulic oil and clean tank of x x
possible impurities
8.Change brake oil and clean tank of x x
possible impurities
9.Check the pressure of possible pressure accumulators in sys- x x
tem
10.Change cabin transfer hydraulic oil 1)
1) Every two years
00.9.5 Scheduled Maintenance for Boom

Dai 50 250 500 1000 once a
BOOM year
ly h h h h
1. Lubricate the slide pieces in boom front end 1) x
2. Lubricate bearings of the boom 1) x
3. Lubricate sliding surfaces of inner boom x
4. Lubricate boom support rollers x
5. Check sliding pads x
1) Daily lubrication, if there is not central lubrication.
00.9.6 Scheduled Maintenance for Spreader

Dai 50 250 500 1000 once a
SPREADER year
ly h h h h
1. Lubricate bearings of longit. tilting cylinders 2) x
2. Lubricate bearings of lengthening cylinders 2) x
3. Lubricate rocker bearings of turning device 2) x
4. Lubricate bearing of turning device 2) x
5. Lubricate slide planes x
6. Lubricate bearings of bearer x
7. Lubricate gear rim x
8. Lubricate twistlocks x
9. Lubricate bearings of twistlock turning cylinder x
10. Check rotation transmission oil level x
11. Change oil to rotation transmission x
12. Check sliding pads x
13. Inspection of twistlocks 3) x
2) Central lubrication point (optional equipment)
3) First time 5000 operating hours or 2 years whichever occurs first.

00.9.7 Scheduled Maintenance for Others

250 500 1000 2000 once a
OTHERS Dai-ly year
h h h h
1.Fill lubricant tank of central lubricational system, (optional equip- x
ment)
2.Check instrument panel, indication lights and signal horn x
3.Check operation of central lubricator dispencers and condition of x
pipes
4.Check operation of electric devices x
5.Check by driving all machine function x

6.Check brake system for possible oil leaks x
7.Measure braking system pressures x
8.Check screw connections and tighten them as necessary to speci- x
fied torques
9.Wash the whole machine throughly clean x
10.Check the operation of the overload control system and adjust it x
if necessary
11.Clean fuel tank of possible impurities x x

00.9.8 Unit Conversation
Convert to SI-units
Old unit Coefficient Si-units
1 kp....... 9,80665 .. N
1 kpm....... (9,81) .. Nm = J = Ws
1 kpm/s....... (10) .. W = J/s = Nm/s
1 kp/mm2....... .. N/mm2 = MPa
1 mm vp....... .. Pa
98,1
1 kp/cm2....... 0,980665 .. kPa

(0,98)
(1,0)
1 mmHg....... 133,322 .. Pa
1 atm....... 101,325 .. kPa
1 bar....... 100 .. kPa
1 hv....... 0,7355 .. kW
(0,75)
1 hp....... 0,7457 .. kW
1 cal....... 4,1868 .. J = Nm = Ws
1 kcal/kg....... (4,19) .. kJ/kg
(4,2)
1 kWh....... 3,6 .. MJ
1 km/h....... 0,278 .. m/s
1 mpk/h(solmu) .... 0,514 .. m/s
1 m3/h....... 0,000278 .. m3/s
1 l/min....... 0,00167 .. m3/s
1 kcal....... 1,163 .. Wh
1 kcal/h....... (1,16) .. W
(1,2)
Note!Calorie (cal) from Ws

1 kWh = 860 kcal = 3,6 MJ

Convert to old units
Si-units Coefficient Old unit
N....... 0,101972 .. 1 kp
Nm = J = Ws....... (0,102) .. 1 kpm
W = J/s = Nm/s .... (0,1) .. 1 kpm/s
N/mm2 = MPa .... .. 1 kp/mm¡
Pa....... .. 1 mm vp
1 Pa....... 0,0010 .. bar
0,0075 .. mm Hg
0,00987 .. atm
1 kPa....... 0,010 .. bar
0,0102 .. kp/cm2
0,000102 .. kp/mm2
1 bar....... 1,02 .. kp/cm2

(1,0)
1 MJ....... 0,278 .. kWh

(0,3)
1 kJ/kg....... 0,239 .. kcal/kg

1 J = Nm =Ws....... (0,24) .. cal
(0,25)
1 Wh....... 0,859845 .. kcal

1 W....... (0,86) .. kcal/h
1 kW....... 1,36 .. hv
1,34 .. hp
1 m/s....... 3,6 .. km/h

1,94 .. mpk/h (knot)
1 m3/s....... 0,0036 .. m3/h

0.060 .. l/min
Note!All the above presented conversion coefficients are approximations of

some degree.
Length
1 in = 25,4 mm 1 mm = 0,039 in
1 ft = 0,3048 m = 304,8 mm 1 cm = 10 mm = 0,39 in
1 yd = 0,9144 m = 914,4 mm 1 dm = 10 cm = 3,9 in

Length
1 naut. mile = 1852 m 1 m = 10 dm = 3,28 ft
1 stat. mile = 1609 m 1 km = 1000 m = 1090 yd
Area
1 sq in = 645,2 mm2 1 mm2 = 0,0015 sq in
1 sq ft = 0,09290 m2 1 cm2= 100 mm2 = 0,15 sq in
1 sq yd = 0,8361 m2 1 dm2 = 100 cm2 = 15 sq in
1 sq mile = 2,590 km2 1 m2 = 100 dm2 = 1,19 sq yd = 10,76 sq ft
1 km2 = 1000000 m2
= 0,38 sq mile
Volume
1 US fl oz = 29570 mm3
1 cu in = 0,01639 dm3
1 cu ft = 0,02832 m3
1 cu yd = 0,7646 m3
1 US qt = 0,9464 dm3
1 US gal = 3,785 dm3
Mass
1 oz = 28,35 g 1 g = 0,0353 oz
1 lb = 0,4536 kg 1 kg = 1000 g = 35,3 oz
1 short ton = 0,9072 t 1 kg = 2,205 lb
1 long ton = 1,016 t
Force
1 ozf = 0,2780 N 1 N = 3,597 ozf
1 lbf = 4,448 N 1 N = 0,2248 lbf
1 kp = 9,807 N 1 N = 0,1020 kp

Pressure
1 ft H2O = 2,989 kPa 1 bar = 100 kPa = 100000 Pa
1 in Hg = 3,386 kPa 1 kPa = 7,5 mmHg
1 in H2O = 0,2941 kPa 1 kPa = 0,33 ft H2O
1 psi = 1 lbf/sq in = 6,895 kPa 1 kPa = 0,29 in Hg
1 kPa = 4,01 in H2O
1 kPa = 0,15 psi
1 kPa = 0,15 lbf/sq in
Energy
1 Btu = 1055 Nm = 1055 J 1 Nm = 1 J = 1 Ws
1 ft-lbf = 1,356 Nm 1 kJ = 1000 Nm = 0,95 Btu
1 kcal = 4187 Nm 1 Nm = 0,74 ft-lbf
1 Wh = 3600 Nm 1 kJ = 0,24 kcal
1 Ws = 1 Nm 1 kJ = 0,00028 Wh
1 kpm = 9,807 Nm 1 Nm = 0,102 kpm
Power
1 Btu/hr = 0,2931 W 1 W = 3,412 Btu/hr
1 ft-lbf/s = 1,356 W 1 W = 0,7376 ft-lbf/s
1 hp = 0,746 kW = 746 W 1 kW = 1000 W = 1,341 hp
1 hv = 0,736 kW = 736 W 1 kW = 1000 W = 1,359 hv
Temperature
°C = 5/9 X (°F-32)
°F = 9/5 X °C+32
K = °C + 273,15

00.9.9 General Tightening Torques
General tightening torques for screw connections, metric ISO-standard thread
Screw size Tightening torque Nm
Strength class, surface treatment, material
5.8 8.8 8.8 10.9 12.9

Zne oiled Zne oiled oiled
M4 1,77 - - - -
M5 3,53 6,35 5,66 8,94 10,7
M6 6,04 10,9 9,69 15,3 18,3
M8 14,5 26,1 23,2 36,8 44,1
M10 28,6 51,5 45,8 72,4 89,9
M12 49,7 89,4 79,6 125 151
M14 79,0 142 127 200 239
M16 121 218 194 307 368
M18 169 304 271 428 513
M20 236 426 379 598 718
M22 319 573 510 806 967
M24 409 735 655 1030 1240
M27 591 1060 943 1490 1790
M30 807 1450 1290 2040 2450
M33 1090 1950 1740 2750 3290
M36 1410 2520 2243 3550 4260
M39 1800 3240 2880 4560 5460
M42 2250 4020 3580 5660 6790
- 1 Nm = 0,102 kpm
- Zne = electrogalvanized
If the screw shank is reduced in diameter (thinned) or the thread terminates in a clear end groove, the values
listed in the table must not be used. Tightening torques for these cases must be calculated separately.

Power Unit 1
01 Power Unit
01.1 Power Unit - Scania ........................................................................................ 3
01.2 Power Unit - Cummins .................................................................................. 4

01.2.1 Tightening Connection between Engine and Transmission ................. 5
01.3 Engine - Scania .............................................................................................. 6
01.4 Engine - Cummins .......................................................................................... 8

01.4.1 Maintenance Points for Fuel Tank and Coolant Expansion Tan .......... 9
01.5 Transmission CLARK 15.5 36431 ............................................................... 11

01.5.1 Checking Transmission Oil Level ...................................................... 11
01.5.2 Changing Transmission Oil ................................................................ 11
01.5.3 Transmission CLARK 15.5 36431 ..................................................... 12
01.5.4 Cross Section of Transmission .......................................................... 13
01.5.5 Oil Pump ............................................................................................ 14
01.6 Instructions for Checking Transmission Operation ................................. 15

01.6.1 Electric Inspections ............................................................................ 15
01.6.2 Hydraulic Inspections ......................................................................... 15
01.6.3 Pressure Measuring ........................................................................... 15
01.6.4 Selector Valve .................................................................................... 16
01.6.5 Measuring Points ............................................................................... 17
01.6.6 Troubleshooting ................................................................................. 18
01.6.7 Tightening Torques of Transmission Bolts and Screws ..................... 19
01.7 Stall Use: Testing of Engine and Transmission ........................................ 20

01.7.1 Testing ............................................................................................... 20

2 Power Unit

Power Unit 3
01.1 Power Unit - Scania
4 5
11
1 6 7
9 3 2 10
Y3
Y2
Y1
Y4
Y5
8
Figure 1. Power Unit
1 Engine
2 Transmission and the torque converter
3 Transmission pump
4 Engine oil dipstick
5 Engine oil filling
6 Oil cleaner
7 Oil filter
8 Fuel filter
9 Transmission oil filling
10 Transmission oil dipstick
11 Transmission oil filters
Weight of power unit 1930 kg (4250 lb)

4 Power Unit
01.2 Power Unit - Cummins

1 2
Figure 2. Power Unit
1. Engine
2. Transmission and the torque converter
Weight of power unit 1930 kg (4250 lb)

Power Unit 5
01.2.1 Tightening Connection between Engine

and Transmission
A
C
B
45 Nm
(33 lbf.ft)
71...77 Nm (52,5...57 lbf.ft)
CUMMINS L10, M11: 185 Nm (136,5 lbf.ft)

SCANIA DS11: 190 Nm (140,5 lbf.ft)
Figure 3. A = Engine B = Transmission
If the tension discs connecting transmission and engine;

point 1; shall be changed, check by mounting that the
new discs are suitable. They must be closed against the
surfaces of engine and transmission. If not, remove with
grindstone the sharp edge of the disc opening.
Engine flywheel housings face of joint (C) SAE

J617 No. 3.

6 Power Unit
01.3 Engine - Scania

Scania DI12 turbocharged and recooled direct injection
engine, low emissions.
Principal dimensions and data

Power 243 kW (330 hv) / 2100 rpm
Max. torque 1458 Nm / 1300 rpm
Number of cylinders 6
Cylinder numbering from the front 1-2-3-4-5-6
end
Engine displacement 11.7 dm3
Cylinder bore 127 mm
Stroke 154 mm
Aspiration turbocharged
Cooling by liquid
Direction of rotation of the crankshaft clockwise
viewed from engine front end
Dry weight 995kg

Power Unit 7
17 9
1, 2
14 19
8
11
15
13
12
16 18
10 3 7 4 5 6
Figure 4. Engine
1 Type plate
2 Engine serial number, stanped in engine block
3 Oil cooler
4 Dipstick
5 Oil cleaner
6 Oil filter
7 Draining, engine oil
8 Cooland pump
9 Charger air cooler
10 Turbocharger
11 Hydraulic pump
12 Control unit A96
13 Starter motor
14 Fuel filter
15 Automatic belt tensioner
16 Draining, coolant
17 Oil filling
18 Fuel hand pump
19 Compressor
For complete details and instructions on the engine, see

the Operator’s Manual.

8 Power Unit
01.4 Engine - Cummins

Cummins QSM11 turbocharged and recooled low emis-
sion diesel engine, which fullfills emission and regulations
step III.
Figure 5. Cummins QSM11 Engine
Principal dimensions and data

Power 246 kW (330 hv) / 2100 rpm
Max.torque 1458 Nm / 1300 rpm
Number of cylinders 6
Cylinder numbering from the front 1-2-3-4-5-6
end
Engine displacement 10.8 dm3
Cylinder bore 125 mm
Stroke 147 mm
Aspiration turbocharged
Cooling by liquid
Direction of rotation of the crankshaft clockwise
viewed from engine front end
Dry weight 940 kg
For complete details and instructions on the engine, see

the Operator’s Manual.

Power Unit 9
01.4.1 Maintenance Points for Fuel Tank and

Coolant Expansion Tan
A
3 2
4
Figure 6. Maintenance Points for Fuel Tank and
Coolant Expansion Tank
A Checking hose
B Filling cap of coolant system
1 Coolant expansion tank
2 Fuel tank
3 Filling of fuel system
4 Draining plug
5 Sensor of fuel level

10 Power Unit
01.4.1.1 Air Cleaner
3 4
2
1
Figure 7. Air Cleaner
1 Main filter element

2 Safety element
3 Prefilter
4 Air cleaner maintenance indicator
5 Indicator reset
The air filter element must be replaced immediately when
the indicator (4) shows red. After replacing the filter ele-
ment, reset the indicator using the button (5).
Clean the pre-filter (3) frequently enough, daily in dusty con-
ditions.

Power Unit 11
01.5 Transmission CLARK 15.5 36431

The Clark transmission incorporates two main compo-
nents: the torque converter and gearbox. The assembly
is mounted as one unit to the flywheel housing of the en-
gine.
01.5.1 Checking Transmission Oil Level

Oil level is checked daily with the engine running at idle
speed and the oil temperature at normal level 82 to 93°C
(180 to 200 °F).
If the oil temperature is below 82°C (180 °F), it must be

warmed up. Run the engine at 20 to 30 r/s (1200-1800 r/
min) with the highest speed range selected (lever in ex-
treme position away from driver) while applying brakes
(STALL). The oil level must be on the highest level plug.
Warning!
Do not use the converter transmission in stall-use
continuously more than 30 seconds that the torque
converter does not become too warm. Keep between
the stall-uses a pause of about 1 minute.
01.5.2 Changing Transmission Oil

Drain out the used oil when its temperature is 65 to 95°C
(150 to 203 °F). The drain plug is under the transmission.
Remove the oil sump screen, clean it thoroughly, and re-

install. Remove the oil filter, remove the cartridge, clean
the housing, install a new cartridge and reinstall the filter.
Fill the gearbox with clean oil up to the lower mark level.
Check the oil level with the dipstick located to the right of
the cabin (beside oil filling cap). Run the engine at idling
speed to fill the torque converter and the pipelines with
oil. Add oil up to the upper plug while the engine is run-
ning. Final inspection of oil level is done when the oil is at
normal operating temperature 82-93°C (180-200 °F).
For oil quality, filling capacity, see Lubrication Oil Recom-

mendations and changing interval, see Scheduled main-
tenance.

12 Power Unit
01.5.3 Transmission CLARK 15.5 36431

630 rpm Min. 40 l/min (10 USgal/min)
2300 rpm Max. 140 l/min (37 USgal/min)
Main pressure
Breather Converter inlet measuring point
Oil fill Oil dipstick
Converter
Oil cooler
out
From oil cooler
Lube pressure
Fwd. clutch Control valve
4th clutch
pressure port
Oil filters (2 pcs)
From filter This line: 117 l/min

(31 USgal/min)
Measuring point for converter

output pressure
Measuring point for converter

output temperature
3rd speed clutch
1st speed clutch pressure port
pressure port Oil sump intake screen
Oil drain plug
Figure 8. Transmission CLARK 15.5 36431

Power Unit 13
01.5.4 Cross Section of Transmission
1 st
2 nd
3 rd
4 th
Figure 9. Cross Section of Transmission

14 Power Unit
01.5.5 Oil Pump
Torque converter
safety valve
Main pressure
measuring point
Pressure regulat-
ing valve
Figure 10. Oil Pump

Power Unit 15
01.6 Instructions for Checking

Transmission Operation
01.6.1 Electric Inspections
Check the functioning of conductors, sensors, connectors
and solenoid valves in the electric system of the transmis-
sion control.
01.6.2 Hydraulic Inspections

Check the transmission oil level before checking the oil
pressures and volume flows of the transmission and
torque converter.
01.6.3 Pressure Measuring

When checking pressures keep the engine speed at 33 r/
s (2000 RPM), and make sure that the speed range se-
lector is in the neutral position.
Clutch Pressures: Normally 17 to 19 bar (240-280 PSI)
Allowed deviation in all clutch pressures in the same con-

ditions is 0,34 bar (4 PSI).
Torque Converter Outlet Pressure:

Min 1,7 bar (25 PSI) / 2000 RPM
Max 4,9 bar (70 PSI) / unloaded at max . speed
Converter Outlet Lines Flow: 90 l/min (24 USgal/min)
For measuring points, see the illustration in this chapter.

16 Power Unit
01.6.4 Selector Valve
12/24 Volt
Figure 11. Selector Valve

Power Unit 17
01.6.5 Measuring Points
Figure 12. Measuring Points
Pressure measurement Measuring point

Clutch pressure, forwards FC
Clutch pressure, 2nd 2C
Clutch pressure, reverse RC
Pilot pressure, forwards FP
Pilot pressure, reverse RP
Pilot pressure, 3rd gear 3P
Pilot pressure, 2nd gear 2P
Pilot pressure, 1st gear 1P
Clutch pressure, 1st gear See section 01.5.3 Transmission
CLARK 15.5 36431
Clutch pressure, 3rd gear See section 01.5.3 Transmission
CLARK 15.5 36431
Clutch pressure, 4th gear See section 01.5.3 Transmission
CLARK 15.5 36431

18 Power Unit
01.6.6 Troubleshooting
Fault Cause Remedy

Low clutch pres- • Low oil level • Fill to proper level
sure • Clutch pressure regulat- • Clean valve spool and
ing valve spool stuck housing
open • Replace pump
• Faulty feed pump • Replace sealing rings
• Broken or worn clutch • Clean bleed valves
axle or piston sealing thoroughly
rings
• Clutch piston bleed
• valve
stuck open
Low output of con- • Low oil level • Add oil
verter feed pump • Intake screen dirty • Clean intake screen
• Air leak in pump feed • Tighten all connections
hose, connections, or and replace hose as
broken hose necessary
• Damaged oil pump • Replace pump
Overheating • Worn oil seeling rings • Inspect and repair con-
verter
• Worn oil pump • Replace pump
• Low oil level • Add oil
• Air leak in pump intake • Check and tighten oil
sleeve sleeve connections
Noisy converter • Worn coupling gears • Replace
• Worn oil pump • Replace
• Worn or damaged bear- • Complete overhaul to
ings determine damaged
bearing
Lack of power • Low Stall speed of • Adjust engine correctly
engine See "Overheating" for
• Cf. "overheating" repair instructions

Power Unit 19
01.6.7 Tightening Torques of Transmission

Bolts and Screws
Grade 5
Nm (kpm) (lbf.ft)
Thread size
Fined thread Coarse thread
3/8" 35-39 (3,6-4,0) (26-29) 31-34 (3,2-3,5) (23-25)
7/16" 56-61 (5,7-6,2) (41-45) 50-56 (5,1-5,7) (37-41)
1/2" 87-95 (8,9-9,7) (64-70) 77-85 (7,9-8,7) (57-63)
9/16" 123-136 (12,6-13,9) (91- 111-122 (11,3-12,4) (82-90)
100)
Grade 8
Nm (kpm) (lbf.ft)
Thread size
Fined thread Coarse thread
3/8" 50-55 (5,1-5,7) (37-41) 45-49 (4,6-5,0) (34-36)
7/16" 79-87 (8,1-8,9) (58-64) 71-77 (7,2-7,9) (52-57)
1/2" 122-134 (12,4-13,7) (90-99) 109-120 (11,1-12,2) (80-88)
9/16" 174-191 (17,7-19,4) (128- 156-172 (15,9-17,6) (115-
141) 127)

20 Power Unit
01.7 Stall Use: Testing of Engine and

Transmission
With help of STALL use the engine and transmission con-
dition will be tested.
Check the STALL running speed of this machine in the

user's manual chapter Technical Information. Compare
this value with running speed value in STALL use.
If the STALL- running speed is lower than the given en-

gine STALL-running speed, the engine function has to be
adjusted and / or repaired.
If the measured STALL-running speed is higher than the

given engine STALL-running speed, the transmission
function has to be adjusted and/or repaired.
01.7.1 Testing
Select the driving direction forwards and engage the high-
est gear. Keep the brake pedal engaged and rev the en-
gine speed up to the highest running speed. Compare the
highest running speed with the given STALL- speed of
the machine.
Warning!
Do not use the converter transmission in stall-use
continuously more than 30 seconds so that the
torque converter does not become too warm. Keep
between the stall-uses a pause of about 1 minute.

Power Transmission 1
02.1 Power Train Components - Scania .................................................. 3
02.1.1 Main Components of the Power Train .................................... 3
02.2 Power Train Components - Cummins ............................................. 4

02.2.1 Main Components of the Power Train .................................... 4
02.3 Drive Shaft ......................................................................................... 5

02.3.1 Change Differential Gear Unit Oil ........................................... 5
02.3.2 Change Planetary Gear Units Oil ........................................... 5
02.3.3 Construction of the Wheel Hub ............................................... 7
02.3.4 Torque Chart: Wheel Hub and Brake Housing ....................... 8
02.3.5 Brake Housing Cover .............................................................. 9
02.3.6 Friction Discs for Brake ......................................................... 10
02.3.7 Housing Pressure Measuring for Coolant Fluid .................... 10
02.3.8 Tightening of the Wheel Hub ................................................ 11
02.3.9 Instruction for Pinion Shaft Bearings .................................... 12
02.3.10 Rolling Resistance of Differential Bearings ......................... 15
02.4 Steering Axle ................................................................................... 17

02.4.1 Installation of Steering Axles ................................................ 19
02.4.2 Tightening and Lubrication of Wheel Bearings ..................... 20
02.4.3 Turning Resistance Control of the Steering Pivot Bearings .. 22
02.5 Wheels .............................................................................................. 23

02.5.1 Tyre Pressure ....................................................................... 23
02.5.2 Torque of Wheel Nuts ........................................................... 24
02.5.3 Checking of the Rims ............................................................ 25


02.1 Power Train Components - Scania

02.1.1 Main Components of the Power Train
5 2
3 4
Figure 1. Main Components of the Power Train
1. Engine
3. Prop shaft and the spring-loaded disc brake as a park-

ing brake
4. Drive axle with differential, drive shafts and planetary

gears in the both axle ends
5. Transmission pump

02.2 Power Train Components -

Cummins
02.2.1 Main Components of the Power Train
5 2
3 4
Figure 2. Main Components of the Power Train
1. Engine
3. Prop shaft and the sring-loaded disc brake as a park-

ing brake
4. Drive axle with differential, drive shaft and planetary

gears in the both axle ends
5. Transmission pump

02.3 Drive Shaft

The casing of the drive shaft assembly mounted rigidly to
the machine frame is of sturdy steel casting construction.
On the ends of the drive shaft are planetary gear unit and
the hubs. On the hubs are mounted wet disc brakes, free
of maintenance.
In a new and/or renovated machine the oil for the differ-

ential or planetary gear unit must be changed first time af-
ter 150 operating hours and after it regularly at 1000
operating hour intervals, yet at least twice a year.
02.3.1 Change Differential Gear Unit Oil

It is better to drain direct after driving because the warm
oil runs faster out of the differential. Open the drainage
plug on the bottom of the differential case to drain the oil
out (see figure).
Filling is done through the filler plug and in such a way

that the oil starts to flow back from the filler opening (see
figure). Oil quality and volumes are defined in the mainte-
nance group 00 "Recommended lubricants and fluids".
02.3.2 Change Planetary Gear Units Oil

The oil change interval of the planetary gear units and the
oil grade to be used are the same as in the differential
gear assembly. Before the drain plug of the planetary
gear unit is opened, the wheel must be turned so that the
drain/filling plug will be in the bottom position. Before oil
filling turn the wheel so that the drain/filling plug is in up-
per position. Fill oil until it starts to flow out of the opened
oil level opening (see figure).

2250 Nm
A B 3
1
2
4
A Differential gear unit

1 Oil level and fill plug
2 Drain plug
B Planetary gear unit
3 Drain/fill plug
4 Oil level plug
Adhere to cleaness when changing the oil. Remember to

check the tightness of threaded plugs after filling.

02.3.3 Construction of the Wheel Hub
Wheel (rim) Planetary Piston return Piston return spring

wheel hub O- ring
spring hub Brake housing
Ring gear Return spring quide
Roll pin Brake housing cover

Wheel nut Plug
Connector
and stud Ring gear hub
Plug
Piston
Planetary gear
Lockwire
Capscrew Hub bearing
Cover Hub seals
Bearing
Sleeve
Hub nut
Adjusting disc
Sun gear Seal wear
Locking ring
Sealing of the hub

Hub bearing lock
disc and screw
O- ring
Plug
Screw
O- ring
Piston seals
Stationary disc Cover screw
Seals Friction disc
Housing to stationary disc spacer
Figure 3. Construction of the Wheel Hub

02.3.4 Torque Chart: Wheel Hub and Brake

Housing
2 3
Figure 4. Wheel Hub and Brake Housing
Torque
No: Description Size
Lbf.ft Nm
1 Cover-to-planetary spider capscrew 7/16" - 14 60-75 82-102
1/2" - 13 85-115 116-156
2 Piston return spring plug - 61-75 81-102
3 Cover and spindle-to-axle housing cap- 5/8" - 11 180-230 244-312
screw - internal mount 3/4" - 10 310-400 450-542
7/8" - 9 500-650 678-881
7/8" - 14 500-650 678-881
1" - 12 725-950 938-1288
1-1/4" - 12 1700-2200 2305-2983
4 Cover and spindle-to-axle housing cap- M16 x 2.00 199-258 270-350
screw - external mount M20 x 2.50 369-479 500-650
5 Planetary spider-to-wheel hub capscrew 3/8" - 16 35-50 48-68
1/2" - 13 85-115 116-156
3/4" - 10 310-400 450-542
6 Bearing adjusting nut lock plate screw 3/8" - 16 35-50 48-68
7/16" - 14 60-75 81-102
7 Cover-to-brake housing capscrew 9/16" - 12 125-165 169-224
M16 x 2.00 199-258 270-350
M20 x 2.50 369-479 500-650

02.3.5 Brake Housing Cover
1 2
3
4 5
9
11
12 6
10
7
9 8
Figure 5. Braking House Cover
Torque
No: Description
Lbf.ft Nm
1 Hydraulic bleeder 15-20 20-27
2 Plug 10 min. 14 min.
3 Housing cover plug 20 min. 27 min.
4 Coolant fill/level plug 35 min. 47 min.
- Sump cooling only
6 Hydraulic fluid inlet fitting 25-31 34-47
- Tapered seat
7 Hydraulic fluid inlet fitting 25-35 34-47
- O-ring
8 Magnetic drain plugsg 20 min. 27 min.
- Cooling system
9 Coolant input port plugs 60-75 81-102
10 Hydraulic fluid inlet 25-35 34-47
12 Coolant output port plugs 60-75 81-102
Note! Removing air from the brake housing takes about

ten times more time than by usual brakes. This is due to
the big capacity of the housing.

02.3.6 Friction Discs for Brake
Figure 6. 1 = Stationary disc 2 = Friction disc
Checking the wear of the brake friction discs:
Friction disc diameter Minimum thickness

13" 3,81 mm
17" 4,31 mm
22" 5,08 mm
02.3.7 Housing Pressure Measuring for Coolant

Fluid
Figure 7. Pressure Level in the Coolant Output is 1 "0.5

Bar

02.3.8 Tightening of the Wheel Hub
Figure 8. 1 = Adjusting nut 2 = Locking plate
Adjust the wheel hub bearings as follows:
1. Tighten the axle nut to 1355-1630 Nm (1000-1200

lbf.ft) pretorque, so that the bearings are without clear-
ance in the wheel hub.
2. Turn the hub 5-10 turnings in both directions.
3. Open the axle nut half turn and turn the hub 3-5 turn-
ings in both directions.
4. Tighten the axle nut to 745-815 Nm (550-600 lbf.ft)

torque with new bearings and 500-550 Nm (370-407
lbf.ft) with used bearings.
5. Turn the hub 5-6 turnings and check the torque value.
Tighten if needed.
6. Lock the axle nut with the locking plate.
7. If you cannot tighten the locking plate so tighten the

axle nut, until the mounting of the locking plate is pos-
sible.

02.3.9 Instruction for Pinion Shaft Bearings
Figure 9. A = Spacers B = Stamped number
Disassemble the bearings of the pinion shaft. Measure

the thickness of the spacers located between the faces,
and check the pinion shaft end for the number stamped to
it. If the number is an integer, the value is defined as thou-
sandths of an inch, and if the number is a decimal, the val-
ue is defined as hundredths of a millimetre.
Example: +3 or -3 =.003" and +.03 or -.03 =.03 mm.
Calculate the nominal spacer thickness according to the

following examples. Take the value of the number
stamped on the pinion shaft and add it to the old spacer
thickness. The sum is the thickness of the new spacer
when installing the bearings of a new pinion shaft.
Calcuting examples of the thickness of spacer between

pinion shaft bearings
Example 1:
Thickness of old space 0,76 mm (0.030")
Number stamped on old pinion shaft -2 -0,05 mm (0.002")
Nominal spacer thickness 0,71 mm (0.028")
Number stamped on new pinion shaft +5 +0,13 mm (0.005")
Thickness of new spacer 0,84 mm (0.033")

Example 2
Thickness of old space 0,76 mm (0.030")
Number stamped on old pinion shaft 2 -0,05 mm (0.002")
Nominal spacer thickness 0,81 mm (0.032")
Number stamped on new pinion shaft +5 +0,13 mm (0.005")
Thickness of new spacer 0,94 mm (0.037")
02.3.9.1 Rolling Resistance of Pinton Shaft Bearings
Figure 10. F = Force A = Sleeve
The rolling resistance is 0.56-5.08 Nm (0.41-3.75 lbf.ft)

with new bearings.
The rolling resistance with used bearings is 1,13-3,39 Nm

(0.83-2.50 lbf.ft).

02.3.9.2 Torque Value of the Nut on Drive Pinion
Figure 11. 1 = Flange bar
Torque values:
Thread size Torque value
7/8" - 20 271 - 373 Nm
1" - 20 407 - 542 Nm
1 1/4" - 12 949- 1220 Nm
1 1/4" - 18 949 - 1220 Nm
1 1/2" - 12 1085 - 1491 Nm
1 1/2" - 18 1085 - 1491 Nm
1 3/4" - 12 1220 - 1627 Nm
2" - 12 1627 - 2034 Nm

02.3.10 Rolling Resistance of Differential

Bearings
Figure 12. 1 = Adjusting Ring
Use the adjusting ring to set the rolling resistance of the

differential bearings to 1.7-3.9 Nm (1.3-3.0 lbf.ft).
Adjust the backlash between the pinion and the crown

wheel to 0.20-0.46 mm (0.008"-0.018") with a used
wheel pair, and to 0.30 mm (0.012") with a new wheel
pair.


02.4 Steering Axle

The steering axle is one swing axle pivoted longitudinally
on the machine frame with two pivot-axles (1). The over-
load control gauge (2) is mounted to the Pivot-axle to
measure the shear force acting on the axle, (optional).
Turning of the wheels is performed by one steering cylin-

der (3) with one piston rod passing through. Strong stub
axles (4) are mounted with sliding bearings (5) to the ax-
les. Disk brakes (11) for steering axle, (optional).

1.2
B
B
A
A
5
6.7
4 1
8 9 10
6
5
A-A B-B C-C
Figure 13. Steering Axle
1 Pivot-axle
2 Overload control gauge (optional)
3 Cylinder
4 Axle spindle
5 Sliding bearing
6 Sliding ring
7 Bearing
8 Axle
9 Cone bearing
10 Retainer screw

02.4.1 Installation of Steering Axles

Install the pivot axles and bearing housings into place.
Secure axle retainer screw (1) with a screw locking.
Set the axles into place.
Tighten the fixing screws (2) of the bearing housings to a

tightness of 380 Nm (280 lbf.ft).
Make sure that the axles are in place and that they are
free from backlash tighten up fixing screw (3).
Finally, open the fixing screw (3) 1/4 turns and lock with a
nut (4).
A
2
380 Nm
280 ft- lbf
4
3
A -- A
Figure 14. Installation of Steering Axles

02.4.2 Tightening and Lubrication of Wheel

Bearings
Tightening and lubrication of the wheel hub have to be
performed according to the maintenance table intervals.
D
A
E
B
C
Figure 15. Wheel Hub of the Steering Axle
A Adjusting nut
B Locking plate
C Protecting cover
D Grease nipple
E Locking nut
Measure the continuous rolling resistance, nominal value

is 30-50 Nm ( 22 - 37 lbs / ft ). If the measured rolling re-
sistance differs from the nominal value, remove the pro-
tecting cover of the wheel hub and change the tightness
of the bearing adjusting nut, until the continuous bearing
rolling resistance corresponds with the above-men-
tioned value.
Check by mounting the locking plate between adjustment

and locking nuts, that the shoulder in the axle keyway
prevents the rotation of the locking plate on the axle. Lu-
bricate both sides of the locking plate with grease.
Tighten the locking nut of the bearings to 1000 Nm ( 740

lbs / ft )

Warning!
After tightening check that the continuous rolling re-
sistance of wheel hub is not more than 50 Nm ( 37 lbs
/ ft ).
Turn the edge of the locking plate over the edge of adjust-
ing nut and locking nut and remount the bearing protect-
ing cover.
Lubricate the wheel bearing pumping through the grease

nipple (D) new recommended grease.
02.4.2.1 Lubrication Points of the Steering Axle

In machine without an optional central lubrication the lu-
brication points have to be lubricated manually according
to the lubrication table intervals in this manual.
Pump through the grease nipples shown in the figure be-

low enough grease to the lubrication points.
2
3
4
5
6
Figure 16. Lubrication Points of the Steering Axle

02.4.3 Turning Resistance Control of the

Steering Pivot Bearings
The turning resistance of the pivot bearings is
defined by axial torque of the pivot axle cone
150- 170 Nm bearings. This torque may reduse during the op-
A erating hours of the machine, and at worst
cause damages in stub axle. Check the pivot
bearings turning resistance approximately every
2000 operating hours and adjust if needed the
pivot axial torque.
The axial torque of the pivot axle pivot is correct,

when the starting turning resistance of the pivot
A bearings (A) is 150-170 Nm by turning the wheel
150- 170 Nm hub by the rim (B). The pivot axle pivot must be
released from the lever (C) between cylinder
and stub axle when measuring the turning re-
sistance.
194 Nm
Adjustment of the Turning Resistance
The turning resistance will be adjusted by axial

D tightening of the stub axle pivot: install a shim/
shims (D) into the bearing house of the stub axle
pivot, mount the covering of the bearing house
and tighten the fixing nuts to 194 Nm. The start-
ing turning resistance of the stub axle must be
150-170 Nm measured like before. If the resist-
ance is lower than this value adjust the turning
resistance again.
Figure 17.Turning Resistance of the Stubaxle Pivot

C B

02.5 Wheels
The wheels on the drive- and steering axle are identical
and interchangeable. The drive axle is fitted with double
wheels.
Warning!
It is absolutely necessary that always before tyre
work pressure is removed or reduced to 1 bar
(15PSI).
02.5.1 Tyre Pressure

Driving with underinflated tyres, with lower pressure than
defined in this group, may cause the tyre cords to break,
and the tyre may slip on the rim, causing valve failure.
Over-inflation subjects the tyres to harmful effects of im-
pacts.
Tyre size Tyre pressure

18.00-25PR40 10 bar
18.00-33PR36 10 bar
Figure 18. Tyre Pressure Mark

02.5.2 Torque of Wheel Nuts

Before taking the machine into the service, check the
tightness of all wheel nuts with the wheels lifted up.
Check the driving wheels during running-in after 2, 4 and
8 operating hours. If You change one wheel, check the
tightness of the nuts according to the running-in regula-
tions.
305Nm 400Nm
Figure 19. Checking interval for tyre pressure and torque

of the nuts is 250 operating hours.

02.5.3 Checking of the Rims
Figure 20. Checking of the Rims
During the long operation time the rims can catch fine
cracks and breaks. They can be caused by following rea-
sons:
• Some tyres has been empty or the tyre pressure has

been too low while machine has been loaded.
• The tyre pressure differs from the base value.
• Genuine spare tyres has not been used after the first
installation. The material and strength of non genuine
spare tyres may not meet the requirements of heavy
machines.
• Deformation of the rim caused by external hits.
Measures to be taken
We recommend annual checks for cracks for example us-

ing magnetic particle test (SFS 3286 or DIN 54131).
This can take place during tyre work, one rim after anoth-
er. The rims which has been checked can easily be rec-
ognized, if You mark them with colour, which is changed
every year.
Warning!
It is absolutely necessary that always before tyre
work pressure is removed or reduced to 1 bar
(15PSI).

Check Procedure
1. Deflate the tyre, see figure The wheel
2. Dismount the wheel from the machine
3. Dismount the tyre from the rim.
4. Disassemble the loose parts from the rim, see figure

Rim of the wheel. (loose parts are No. 1 + 3 + 6 + 9).
5. Clean the areas shown ---- down to bare metal (rim

part No. 4 + 8), see figure Rim of the wheel and figure
Gutterband and Backband.
6. The cleaned areas of the rim must be magnetic parti-

cle tested.
7. If cracks or crack indications appear, grind smoothly

maximum 0,5mm in depth. Then carry through a crack
detection test, using the penetrant method (use sol-
vent based penetrant).
8. If no cracks appear after point 6: Approve the wheel.
9. If no cracks appear after point 7: Approve the wheel.
10.If cracks appear after point 7: Reject the wheel.
11.Approved wheel have to be protected against rust

(painted) .
12.Reassemble the tyre and the loose parts, see figure

Rim of the wheel. Make sure that all loose rim parts are
in the correct place.
13.Reinflate the tyre & remount the wheel
14.Records: When the wheel has been checked, mark

the wheel and record the result.
Warning!
Because of the material and manufacturing method
of a rim, it is not advisable to repair a rim by welding.
To avoid uneven load, check the tyre pressure regu-

larly.

Figure 21. Rim of the Wheel
1,9 Flange
2 Lockring driver
3 Locking
4 Gutterband
5 Wheel Driver
6 Beadseatband
7 Centerband
8 Backband
Figure 22. Gutterband and Backband


Hydraulic System 1
03 Hydraulic System
03.1 Operating Principle of Hydraulic System ....................................... 2
03.1.1 Letter and Number Signals in the Hydraulic Diagrams ........... 2
03.1.2 Pumps ..................................................................................... 2
03.1.3 Boom Movement Hydraulic ..................................................... 4
03.1.4 Steering Hydraulics ................................................................. 5
03.1.5 Top-lift Hydraulic ..................................................................... 6
03.1.6 Pre-control Pressure ............................................................... 7
03.1.7 Filtering of Hydraulic Oil .......................................................... 7
03.1.8 Cooling of Hydraulic Oil .......................................................... 7
03.1.9 Clean Hydraulics ..................................................................... 8
03.1.10 Measures to Prevent Pollution of the Hydraulic System ..... 10
03.1.11 Fault Finding for Leakage ................................................... 12
03.1.12 Dismantling Hydraulic Cylinders ......................................... 13
03.2 Hydraulic Brake System ................................................................. 15

03.2.1 General ................................................................................. 15
03.2.2 Brake Hydraulics ................................................................... 15
03.2.3 Adjusting and Measuring Points for Brake System ............... 17
03.2.4 Adjusting of Brake Pressure ................................................. 18
03.2.5 Adjusting the Brake Pedal .................................................... 20
03.2.6 Adjusting the Parking Brake ................................................. 21
03.3 Maintenance of Diaphragm Accumulators ................................... 22

03.3.1 Structure of a Diaphragm Accumulator and Filling Device ... 22
03.3.2 Checking of the Pressure Accumulators ............................... 23
03.3.3 Filling Pressure Accumulators with Nitrogen Gas ................. 25
03.4 Steering Hydraulic System ............................................................. 27

03.4.1 Steering System ................................................................... 27
03.4.2 Steering Device .................................................................... 28
03.4.3 Oil Flow in Load Sensing Steering System ........................... 29
03.4.4 Fault Diagnosis ..................................................................... 30
03.5 Hydraulic Components for Basic Machine ................................... 31

03.5.1 Hydraulic Oil Tank Maintenance Points ................................ 32
03.5.2 Pumps ................................................................................... 34
03.6 Hydraulic Components for the Cabin Transfer ............................ 36

03.6.1 Pressure Adjusting for the Load Control Valve ..................... 37
03.6.2 Pressure Relief Valve (Rv) Adjusting .................................... 37
03.6.3 Oil Changing to the Cabin Transfer Hydraulic ...................... 39
03.7 Hydraulic Components for the Spreader ...................................... 40

03.7.1 Adjusting the Spreader Lengthening .................................... 41

2 Hydraulic System
03.1 Operating Principle of Hydraulic

System
This chapter describes the operating principle of the hy-
draulic system in RS2002 Reach Stacker . Item numbers
in the text refer to the hydraulic diagrams. In operating
principle the numbers of components are marked with pa-
renthesis, for example valve (30).
Electronic solenoid valves, which control actuators or

functions, are shown in the diagrams with the letter Y, for
example Y57. The diagrams are attached to section C of
the manual.
03.1.1 Letter and Number Signals in the

Hydraulic Diagrams
03.1.1.1 Pumps
In a diagram, the maximum volume flow produced by a
pump is marked above the picture symbol of the pump,
e.g. 206 l/min.
03.1.1.2 Pipes and Hoses

Pipes and hoses related to valves and/or actuators are
marked, for example, with letters P and T. P1 is a pres-
sure line, T1 is a return line, TP is a drain line, and LS is
an LS signal line. Letters A, B, show connection items for
valves and actuators, to which pipes or hoses are con-
nected.
03.1.1.3 Valves
Pressure adjustment valves are marked in the diagrams
with letters PM and a number. Adjustment values of pres-
sure adjustment valves with a PS marking are described
in table form in that diagram, where said valve is defined.
For example, from PS 4 valve you adjust the pressure to
a numerical value, which is shown in the table as a nom-
inal pressure value of PM 4 measurement point.
Adjustment values of pressure adjustment valves with a

fixed pressure setpoint are shown in the diagram as a nu-
merical value next to the picture symbol of the adjustment
valve.
03.1.2 Pumps
Pumps for work movements and steering are adjustable-
displacement pumps ( 16.1, 16.2, 17.1), connected with
transmission power converter. Running speed is same as
by diesel engine.

Hydraulic System 3
Pump for top lift movements and extra speed by boom lift-
ing (17.2) is a vane pump. Brake pump (17.3) is a gear
pump. Inner pumps (17.1 and 16.1) are used for boom lift
and telescope movements. Middlemost (17.2) pump is
used for top lift movements and extra speed by boom lift-
ing with light load.
Outer (16.2) pump is used for steering, boom and tele-

scope movements. Brake pump (17.3) acts as a charging
pump for pressure batteries and as a pump for wet brake
cooling.
Pressure reduction valve PS22 (4) in pressure-battery

charging valve is connected to the brake pump pressure
connection, and the pressure reduction valve acts as the
pump's relief valve.
16.1
17.1
16.2
17.2
17.3
Figure 1. Pumps
16.1 Lift and boom in/out

16.2 Steering, lift and boom in/out
17.2 Spreader and fast lifting
17.3 Brakes

4 Hydraulic System
03.1.3 Boom Movement Hydraulic
03.1.3.1 General
Boom lifting and telescope are controlled by proportional
valves controlling the load sensing main valve units. The
pump pressure is determined by drive pressure (load).
Movement speed in lifting and on telescope are adjusted
after start-up phase by changing the pump's output angle
and by altering the diesel engine's running speed. Simul-
taneous movement on boom lifting and telescope e.g.
vertical lifting movement can be performed by operating
two functions of the boom control manual controller simul-
taneously (cross movement lever of boom control).
03.1.3.2 Boom Lifting / Lowering

Boom lifting is performed by means of the single acting
cylinders, because piston arm sides of hoist cylinders
(2.1 and 2.2) are connected to the tank line. Boom lifting
is controlled with proportional valve Y58. Pumps output is
controlled simultaneously for both hoist cylinders. The lift-
ing speed will be adjusted in the beginning stepless by
valve control, by changing pumps' output angles. During
lifting, oil from arm side of hoist cylinders (2.1 and 2.2) is
drained directly through the tank line to the tank. In lifting
lock valves (6.1 and 6.2) do not affect lifting, instead they
let the oil flow unhindered to lifting cylinders (2.1 and 2.2).
Extra speed by boom lifting is acted, when the pressure
of the lifting cylinders is under 90 bar (19.2) B6. Then top-
lift-pumps' output is controlled by solenoid valve Y87 (26)
direct to hoist cylinder, while free circulation valve Y56
(32) is closed.
Boom lowering is controlled with proportional valve Y57 ,
which let the oil from hoist cylinders (2.1 and 2.2) through
main valve (30) to the tank, and at the same time adjust
lowering speed steplessly. Boom hoist cylinders are
equipped with lock valves (6.1 and 6.2 ), which are
opened with a hydraulic control command. Boom is low-
ered because of load and boom weight, so pump output
is not needed for the lowering movement. Lowering
speed is slowed by limit electric adjusting value. When
the boom is lowered, there is formed underpressure at
arm sides of hoist cylinders (2.1 and 2.2), which sucks oil
directly from the tankline to the cylinder arm side.
Pressure at piston side of the lifting cylinder is measured

by pressure transmitter (19.2) B6, and on the basis of
pressure data it sends, electronic control reduces flow of
return oil from lifting cylinders (2.1 and (2.2) on heavy
loads through valve (30) to the tank. It tries, as much as
possible, to electronically adjust lowering speed to be
equal on all loads.

Hydraulic System 5
03.1.3.3 Boom Extend / Retract

Boom extend is controlled by proportional valves Y51,
which are used to guide the volume flow produced by the
pumps to the piston side of the boom's telescope cylinder
(3) through valve (30) A1-port. Oil is drained from the arm
side through B1-gate of valve to tank. Lifting speed is ad-
justed steplessly with valve controls, by changing the
pumps' output angles.
Boom retract is controlled with proportional valve Y52,

which is used to guide oil's volume flow to the piston rod-
der side of the boom's telescope cylinder (3) through
valve (30) B1-port. At the same time telescope's lock
valve (7) is opened, and oil is drained from the piston side
to the tank through the main valve (30) through valve (30)
B1-port to tank. Adjustment of movement speed is done
steplessly with the joystick.
03.1.4 Steering Hydraulics

When machine steering is used, the volume flow pro-
duced by the pump (16.2) goes to the priority valves (27).
In the priority valve the volume flow is divided into two, pri-
marily for use of the steering device (23) and mini steer-
ing control valve (36) and secondarily for use of lifting and
telescoping valve (30).
Steering speed is determined by turning speed of the

steering wheel, by higher speed the priority valve (27) di-
rects stronger flow to the steering cylinders (1).
System is load-sensitive. The load (steering cylinder's

pressure) transmits an LS signal to the pump's adjuster,
which adjusts pump output as necessary. The LS signal
is also transmitted to a priority valve (27), which guides oil
flow to be used by steering. Steering speed and pressure
are determined by adjusting pump output according to the
LS signal received by the steering device. When turning
speed is increased, the priority valve guides a bigger vol-
ume flow through the steering device to the steering cyl-
inders ( 1 ).
Steering circuit is equipped with relief valves which pro-

tect it from outside shocks. The relief valves are located
in a relief valve block in connection with the steering de-
vice (23). Maximum pressure going to steering device
(23) mini steering control valve (36) is limited with LS-sig-
nal's pressure reduction valve adjustment of the priority
valve (27).

6 Hydraulic System
03.1.5 Top-lift Hydraulic
03.1.5.1 General
Top-lift movements are performed by solenoid valves,
some of them are mounted on the top of the boom and
some on the top-lift.
Pressure to the boom upper end is directed through one

extra pressure line from the top-lift pump (17.2) by closing
the free circulation from valve Y56 (32), which is switched
on always, when one of the top-lift movements is in func-
tion. Return oil into the tank is flowing through one extra
tank line. In this line is mounted one 5 bar non-return
valve to prevent the draining of the lenghtening cylinders
and to keep the back edge of the top-lift allways lower
than the front edge.
03.1.5.2 Longitudinal Tilting

In normal function the longitudinal tilting of top-lift is in so
called reducing position (Y63 switched on), the top-lift is
positioned because of the earth gravity in horizontal posi-
tion and the movements for-/backwards are reduced with
throttles (12.3 and 12.4). With a reversible locking switch
the current can be switched off in solenoid Y63, the top-
lift is locked in respect to the boom. It is used specially by
turning the top-lift/container in longitudinal position,
where free movements can be harmful. In this situation
the top-lift will be tilted by means of one special longitudi-
nal tilting switches, which are controlling solenoidvalve
Y65a/b. The tilting speed can be adjusted by throttle
valves (12.1 and 12.2). Shock valves 175 bar (21.1 and
21.2) are mounted in the cylinders.
03.1.5.3 Rotation Motor

Regulating valve Y59 (9) is a proportional valve, which
makes the stepless adjustment of the rotation speed pos-
sible. Rotation circuit is equipped with a 200 bar shock
valve (8), which limits the rotation moment to given max-
imum value and specifies on the other hand the maximum
retarding by stopping to prevent the overloading of the ro-
tation devices. Rotation engine is one slow hydraulic en-
gine, which is mounted in the gear reducer. Between
engine and transmission is one plate-compressor brake.
The brake will be opened automatically by throttle check

valve (13.1) and closed, when the rotation movement is
stopped.

Hydraulic System 7
03.1.5.4 Use of the Twistlocks

Control by solenoid valve Y71a/b and closed / open-posi-
tion of the twistlocks is secured by non-return valves
(32.1 and 32.2).
03.1.5.5 Side Shift

Control by solenoid valve Y62a/b. Motion speed is adjust-
ed by fixed throttles (38.1 and 38.2) and the circuit is
equipped with shock valves (8.1).
03.1.5.6 Adjustment of Gripping Length

Control by solenoid valves (Y73a/b and Y74a/b). By leng-
htening the gripping length the return line will be opened
by non-return valves (33.1 and 33.2).
03.1.5.7 Pile Slope, Optional

Control by solenoid valves (Y73a/b and Y74a/b). By leng-
htening the gripping length the return line will be opened
by non-return valves (33.1 and 33.2).
03.1.6 Pre-control Pressure

Pre-control pressure is taken from pressure line of pumps
and pressure is reduced with a pressure reduction valve
(31). This pressure is used as the pre-control pressure of
the direction valve (30) and mini steering control valve
(36).
03.1.7 Filtering of Hydraulic Oil

Filtering is performed by full flow return filters (15). Abso-
lute filtering value is 10 µm. Filters are equipped with 1
bar electrical pressure-difference sensor and signal light
in the cabin and with one 1,5 bar by-pass valve. The sen-
sor is in function only in temperatures over 20°C to pre-
vent the malfunction signals because of the viscosity
changes in low temperatures.
The main pump can be optionally equipped with a pres-

sure filter (53) with 10 µm filtering value and a visual indi-
cator.
03.1.8 Cooling of Hydraulic Oil

Oil cooler (18) is equipped with electrical fan controlled by
thermostat ( 50°C). The cooler is ptotected against pres-
sure shocks with shock valve of 5 bar.

8 Hydraulic System
03.1.9 Clean Hydraulics

Hydraulic systems are extremely sensitive to impurities -
a hydraulic system is just as sensitive as a diesel engine's
fuel system, with its pumps, filters and lines.
It is therefore extremely important that hydraulic systems

are kept clean and free from impurities. A clean system
means that there are no impurities in the system, whether
it be in the hydraulic fluid, component parts of the system
or hydraulic lines and hoses.
By impurity, we refer to everything and anything that is

not intended to be in the system:
• solid particles such as dust, grit, threads of cotton

waste, flakes of rubber from hoses or seals, etc.
• liquids
• gasses
03.1.9.1 Possible Sources of Impurity

• Existing impurities
- Casting sand, welding cinder, dust, water, etc., from

components, hydraulic lines and hoses.
• Generated impurities
- Scaling. When particles that come between two

moving surfaces attach themselves to one of the
surfaces and thereafter act as a cutting surface to
the opposite surface where it cuts or grinds off ma-
terial. The newly formed particles then harden and
cause even more wear and tear as they circulate in
the system.
- Erosion
- Cutting or "cold welding"
- Cavitation, insufficient flow to pump
- Corrosion that generates particles
- Fatigue/wear and tear that generates particles
• Accidentally added impurities
- During repair operations

Hydraulic System 9
- As a result of topping up with impure hydraulic fluid
• Penetrative impurities
- Penetration via breather air to the hydraulic tank
- Penetration via the piston rod's lubricating film
- Penetration through poorly sealed inspection hatch-

es
- Condensation
- Penetration via rod seals
03.1.9.2 Solid Particles

It is possible to see a particle of 40 µ in size with the na-
ked eye, but not one of 10 µ.. (1 µ = 1/1000 mm).
By comparison, a strand of human hair is approx. 70µ

thick. The smallest particles are less than 25 µ in size and
are not visible to the naked eye.
It is not, therefore, possible to judge, with the naked eye,

whether or not hydraulic fluid is sufficiently clean! A parti-
cle count using special machinery or magnification equip-
ment must be made to establish the degree of impurity.
Solid impurities in hydraulic systems cause many differ-

ent types of problem. Large quantities of impurity dramat-
ically reduce the operative life span of the system.
Hydraulic components break down as a result of internal
wear. Particle accumulation can cause the check valves
and servo valves to jam, which may lead to movement
problems. Some movement might not work, or movement
could be slow or in the wrong direction.
03.1.9.3 Gasses
The most common gas that occurs as an impurity in a hy-
draulic system is air. Unlike fluids, gasses can be com-
pressed. If air is allowed to enter a hydraulic system, this
compression will be experienced as a "sponginess" of op-
eration, making hydraulic movements difficult to control.
Air in the hydraulic fluid can also cause corrosion dam-

age, particularly when localized, sudden reductions in
pressure, known as cavitation, occur.
03.1.9.4 Liquids
The most common liquid impurity that occurs in a hydrau-
lic system is water, for example, through condensation.

10 Hydraulic System
This can cause rust to form, resulting in flakes or particles

of rust entering the system. This most commonly occurs
in the tank and those parts that are above the level of the
hydraulic fluid. Such parts can be inside single action cyl-
inders where the complete length of the hydraulic piston
stroke, is seldom or never used. One simple preventive
measure for such parts is to regularly run all hydraulic
functions to their end positions so that the whole of the
cylinders are lubricated.
03.1.10 Measures to Prevent Pollution of the

Hydraulic System
03.1.10.1 When Changing Attachments

Many machines have attachments that can be changed,
which also means that hydraulic lines and hoses must be
loosened and switched over. This entails a major risk of
impurities penetrating into the system.
• Always clean the connection point extremely thor-

oughly before disconnecting
• If possible, use quick release connectors fitted with a

non-return valve. This will then reduce the risk of impu-
rities entering the system and fluid being spilt
• Clean the connectors extremely thoroughly before

making the connection. Make sure that no impurities
are forced into the connectors themselves.
03.1.10.2 When the System is Operating

All protruding hydraulic components, such as hydraulic
piston rods, are at considerable risk from both mechani-
cal damage and impurities. Due to the fact that the level
of hydraulic fluid in the tank varies, the tank will "breath"
through the breather filter and if the level becomes too
low, the hydraulic pump will fill the system with air.
• Be extremely careful with hydraulic piston rods so as

to avoid physical damage to them
• Regularly empty condensation water from the hydrau-

lic tank
• Make sure that the fluid level in the hydraulic tank is al-
ways right level
• Make sure that all filters in the system function correct-

ly. Regularly replace filter elements, in accordance
with the machine's lubrication chart

Hydraulic System 11
• Regularly check the wiper and rod seals and replace

them as required
03.1.10.3 Storage and Topping up of Hydraulic Fluid

• Be particularly careful when topping up hydraulic fluid
- carelessness is one of the major causes of impurities
entering the system
• Store drums, cans and funnels in as clean conditions

as possible, for example, under a tarpaulin and not di-
rectly on the floor.
• Handle drums, cans and funnels with care and clean

them as necessary
• Store drums of hydraulic fluid horizontally so that

bungs and taps are below the fluid level, which will re-
duce the risk of impurities and humid air entering the
drum.
• Always top-up hydraulic fluid through a clean strainer,

preferably through a filter, using a top-up pump.
• Never use the very last of the fluid in the drum. This
could contain water and other impurities, depending
on the number of times that the drum has been
opened.
• Hydraulic oil provided by oil companies in closed con-

tainers is not clean enough to be used in the hydraulic
system as is. The oil must be cleaned/filtered before it
can be added to the machine's hydraulic oil tank.
03.1.10.4 Repairs and Service

As soon as a hydraulic system is opened, there is always
a great risk of impurities entering the system
• Thoroughly clean the around the area of the system on

which work is to be carried out
• Isolate the area where work is to be carried out with

the help of, for example, clean protective plastic sheet-
ing
• Do not open sensitive components out in the field, re-

place the complete component instead
• Immediately insert protective plugs in all open connec-

tions

12 Hydraulic System
• Make sure that exchange components are thoroughly

clean
• Carry out the repair as soon as possible
• After dismounting, clean all parts
• If a serious breakdown has occurred, for example, if a

pump or hydraulic motor has seized, metal particles
may have been spread and polluted the entire system.
In such cases, it is extremely important to carefully fil-
ter or replace the hydraulic fluid. Under all such cir-
cumstances, the system's filters must always be re-
placed
• Never fit components where the protective plugs have

fallen out - impurities may have entered the system.
Warning!
If there is the slightest doubt about the purity of the
hydraulic fluid - send a fluid sample to the manufac-
turer of the fluid.
03.1.11 Fault Finding for Leakage

• All fault finding should take place with the minimum hy-
draulic pressure required to actually discover the leak-
age. High pressure will tighten all seals and make it
more difficult to discover any leakage.
• Check extremely carefully where the leakage comes

from before taking any action. It may be possible to
stop the leakage without the necessity of costly dis-
mantling.
• Check for external leakage
- welds on cylinder ends
- welds on coupling connections
- Leakage between the cylinder pipe and the cylinder

head, could be due to a faulty O ring or damage to
the O ring's sealing surface. Both problems can be
corrected with the cylinder in place.
- Leakage between the cylinder head and the piston

rod, could be due to a damaged piston rod or dam-
aged/worn piston rod seal.
• Check for internal leakage

Hydraulic System 13
- Leakage between the hydraulic piston seal and the

cylinder pipe, due to worn piston seal. Put the cylin-
der under pressure and check to see if the piston
sinks back.
Warning!
Do not check for leaks with your hand, as even a
small leak could be strong enough to penetrate the
hand. Use a face mask that covers your entire face,
as well as protective clothing and footwear that pro-
vide protection against high-pressure liquid sprays.
Always wear these when working near pressurised
hydraulic hoses, pipes, or components.
03.1.12 Dismantling Hydraulic Cylinders

Before dismantling, always check that the piston rod is
free from any remains of paint. Also check to ensure that
there are no burrs or impact damage by the connections
or couplings. Make sure that the chamfer up to the
chrome surface of the piston rod is free from burrs and
any remains of paint.
• Loosen the cylinder from its mounting and loosen the

hydraulic connections
• Immediately plug the cylinder connections and hoses/

lines.
• When the cylinder is opened - observe the highest

possible level of cleanliness! Study the Technical
Handbook to see how respective cylinders are de-
signed and constructed.
03.1.12.1 Check Surfaces

• Check the surfaces of seals. Always think about how
the seals function and the type of sealing surfaces that
they have. See the following descriptions:
- O ring grooves internal and external
- piston rod seals in the cylinder head
- sealing groove on the piston
- cylinder pipe surface
- piston rod surface. The piston rod has a chromium

plated surface of 20-50 µ in thickness. Very minor
damage to this plated surface will not necessarily di-
rectly result in leakage

14 Hydraulic System
- All sliding surfaces (dynamic surfaces). These are

always the most difficult to ensure a tight seal, for
example, cylinder pipe and piston rod.
Warning!
When fitting the cylinder head: Fit the head absolute-
ly straight, preferably by hand. Do not, under any cir-
cumstances, hit it with a mallet or hammer. If the
cylinder head is fitted askew the lip of the piston rod
seal can be damaged and any sealing function will be
lost. This applies to all types of piston rod seals.

Hydraulic System 15
03.2 Hydraulic Brake System

03.2.1 General
The hydraulic brake system consist of hydraulic pump,
charge valve of brake pressure accumulators, brake
pressure accumulators, pedal valve and wet disc brake of
drive axle.
The parking brake is spring-loaded dry disc brake unit on

the cardan shaft, which can be switched on by the oper-
ating switch in the cabin.
The system is completely hydraulic and controlled by

charge valve, pressure accumulators and brake pedal
valve. The hydraulic pump fills through the charge valve
the pressure accumulators. When they are filled, the
charge valve leads the pressure of the pump to the hy-
draulic system.
The pressure accumulators are selected, so that they

make it possible to brake several times, before pressure
in the accumulators falls below the specified pressure lim-
it and the charge valve switches the pump to fill the sys-
tem. The brake pedal valve controls the hydraulic brake
cylinders in the axle. By adjusting the movement of the
brake pedal the hydraulic pressure to the brake cylinders
can be adjusted.
03.2.2 Brake Hydraulics

Brake hydraulics gets volume flow from the brake pump
(9). The pump gives volume flow to both charging of pres-
sure accumulators of brakes and to cooling of the brakes.
From the pump the oil goes first through a pressure filter
(5) to charge valve of the accumulators, from where it
goes to brake cooling and is distributed evenly to each
brake. From the brakes the cooling oil returns back to the
tank. A thermo bypass valve (18) prevents generation of
excessive cooling pressure inside the brakes, when the
oil is cold.
If pressure in the pressure accumulators has fallen below

about 128bar, accumulators' charge valve charges the
pressure accumulators (8), and when pressure of accu-
mulators is 160bar, the valve switch the pump (9) to free
circulation.
Integrated to the charge valve of accumulators in the

brakes is handbrake valve Y12, which releases hand-
brake cylinder (2) when it is energized. Then pressure of
the hydraulic oil can squeeze in the spring of handbrake
cylinder (2) and release the handbrake. When Y12 is de-

16 Hydraulic System
energized, the spring force pushes hydraulic oil from the

cylinder to the tank, and at the same time spring force
causes braking force on the handbrake.
Brake pedal valve (11) gets pressurized hydraulic oil from

pressure accumulators (8) Pressure accumulators are
so-called diaphragm-type accumulators, with volume of
2,8 litres. Pre-filling pressure is nitrogen gas (service
manual instruction).
Installed into the parking brake circuit is one accumulator

(8.1), and installed into the driving brake circuit are three
corresponding accumulators (8.2,8.3,8.4), which are sep-
arated from each other with counter valves.
Pressure switch S13 in charge valve (4) is switched on, if

pressure in the accumulator circuit is low (115 bar).
Pressure switch (7) S23 for brake lights is switched on, if

pressure is below 2,5bar.

Hydraulic System 17
03.2.3 Adjusting and Measuring Points for

Brake System
PM27 PS22
8.4
PM26
8.3
PM21
8.2
PM24 PM22
8.1
S13
PM23
Drive axle
Y12
17
18
Figure 2. Adjusting and Measuring Points for Brake
System
5 Pressure filter
8.1-8.4 Pressure accumulators
17 Oil cooler
18 Brake tank
PM21 Pressure measuring for charging pressure
PM22 Pressure measuring for accumulator pressure, handbrake
PM23 Pressure measuring for accumulator pressure, footbrake
PM24 Pressure measuring for brake pressure
PM26 Pressure measuring for handbrake
PM27 Pressure measuring for cooling pressure
PS22 Pressure adjusting for charging pressure
S13 Pressure switch for low brake pressure
Y12 Parking brake valve
Numbering corresponds to the brake hydraulics flow-

chart.

18 Hydraulic System
03.2.4 Adjusting of Brake Pressure
PM26
PM26
PM26
PM21
PM22
S13
PM23
Figure 3. Adjusting of Brake Pressure
1. Adjust the pressure adjusting valve PS22 in charging

valve of pressure accumulators full open.
2. Start the engine.
3. Connect the pressure gauges measuring 0-250 bar to

the measuring points PM21 and PM22.
4. Adjust the pressure adjusting valve PS22 to160 bar,

which is the end point of charging and lock the adjust-
ing screw.
5. Check the indication of pressure gauge connected to

measuring point PM21 when the engine is running at
idle. The charging valve of pressure accumulators is
functioning as planned, if the gauge shows 5-10 bar
pressure, when the pressure accumulators are full
charged. When the charging valve is charging the
pressure accumulators, the pressure gauges connect-
ed measuring points PM21 and PM22 show the charg-
ing pressure of that moment. When the adjusted 160
bar pressure is reached, the pressure gauge connect-

Hydraulic System 19
ed measuring point PM22 shows 160 bar and the pres-

sure gauge connected measuring point PM21 shows
5-10 bar.
6. Follow the changes in pressure accumulators charged

hydraulic pressure on the pressure gauge connected
in pressure measuring point PM22, when the engine is
running at idle. The charging valve is functioning as
planned, if the gauge shows 123-132 bar, when the
charging valve starts to charge again the pressure ac-
cumulators. The starting pressure of charging can not
be adjusted. If the starting pressure is under 123 bar,
please inform the manufacturer of the machine for
pressure cartridge calibration.

20 Hydraulic System
03.2.5 Adjusting the Brake Pedal
S52
2,S23
Figure 4. Brake Pedal
1 Brake pedal
2 Brake pedal valve
3 Adjusting screw
S23 Braking light switch, 2.0bar
S52 Declutch

Hydraulic System 21
03.2.6 Adjusting the Parking Brake
1
4
2
3
5
1 4
3
5
Figure 5. Parking Brake
1 Adjust screw
2 Release screw of the parking brake
3 Brake disc
4 Brake pad
5 Locknut
Start to adjust switching the parking brake out of function

(pressure in cylinder) by pressing the operating switch.
Make sure, that the pressure accumulators are charged.
Adjust the nut 5 (picture 1) close and switch the parking
brake on by pressing the operating switch (pressure out
of cylinder). Adjust with hook plug spanner the adjusting
screw 1 and close until the brake pads (4) touch the brake
disc (3). After that open the adjusting screw 1 adjusting
1,5 revolutions. Switch the parking brake out of function
(pressure in cylinder) by pressing the operating switch
and then open the nut 5 (picture 2) ending the adjusting
work.

22 Hydraulic System
03.3 Maintenance of Diaphragm

Accumulators
03.3.1 Structure of a Diaphragm Accumulator
and Filling Device
M28X1.5
SW6
1 17
5
2
8
1/2
6
12 11
3 W24.32x1/13
13 14
SW36
15
4 9
16 M28X1.5
Figure 6. Diaphragm Accumulator and Filling Device
1 Diaphragm accumulator
2 Sealing ring
3 Diaphragm
4 Shut-off valve
5 Shut-off screw
6 Bleed valve
8 Intermediate piece
9 O-ring
11 Non-return valve
12 Connection to nitrogen bottle
13 High-pressure hose
14 Pressure gauge
15 Shut-off screw
16 Diaphragm accumulator
17 Filling device for diaphragm accumulator

Hydraulic System 23
03.3.2 Checking of the Pressure Accumulators
8.1 8.2 8.3 8.4
Figure 7. Pressure Accumulators
During adjustment and maintenance works of the brake

system you must pay special attention to the operating
condition of the pressure accumulators. If the common
pressure accumulators of the whole system are dam-
aged, the charging valve is operating frequently and the
braking effect is declining rapidly when the engine is
stopped. To ensure planned operation of the braking sys-
tem, the pressure accumulators should be checked at
least twice a year. The accumulator used in the brake
system is a precharged diaphragm accumulator with a
non-replaceable diaphragm. The precharging pressure of
the brake system pressure accumulators is 100 bar. An
exact measuring of the precharging pressure and possi-
ble increasing is described in group KH03-0106.
Check the precharging pressure from the "oil side" as fol-

lows:
1. Install a pressure gauge with pressuer area 0-250 bar

to the pressure measuring point PM22.
2. Start the engine and run at idle speed for a while to in-
crease the pressure reading to
150 bar. Stop the engine.
3. Engage the parking brake. If the pressure gauge

shows a reading at the measuring point PM22 still after
several engagings of the parking brake, the accumula-
tor diaphgrams are OK.
4. Checking of the pressure accumulators of the circuits

after non-return valves:

24 Hydraulic System
Install a pressure gauge to the pressure measuring point

PM24. Depress the brake pedal several times while ob-
serving the pressure gauge reading. The pressure drops
when the brakes are applied until the pressure drops very
quickly close to zero. The pressure reading before this
sudden dropping is the precharging pressure of the accu-
mulator to be checked.

Hydraulic System 25
03.3.3 Filling Pressure Accumulators with

Nitrogen Gas
Diaphragm accumulators are precharged with nitrogen
gas to the required precharging pressure before installa-
tion. The precharging pressure for each accumulator is
specified in the hydraulic flowcharts in the operation and
maintenance manuals of the machine. The precharging
pressures specified by the manufactured must absolutely
be observed.
03.3.3.1 Filling
By measuring the hydraulic accumulator make sure that
there is no hydraulic pressure in the system. The oil must
flow free out of the hydraulic accumulator. If there is no
free outflow, the filling pressure may be too low. To empty
the pressure in the hydraulic system, pump the brake
pedal many times.
A filling device is used for precharging pressure accumu-

lators and checking the precharging pressure. First, re-
move the cap and the sealing lacquer on the shut-off
screw. Clean the sealing surface in the end of the accu-
mulator, and the external thread, and loosen the shut-off
screw just a little with an allen key.
Connect the filling device to the pressure accumulator

and the hose to a nitrogen gas bottle. Make sure that the
O-ring is properly positioned between the filling device
and the accumulator sealing surface. Using a square key,
open the pressure accumulator shut-off screw with the
aid of the intermediate piece in the filling device. Open
just enough to get the precharge pressure reading in the
pressure gauge.
If the precharging pressure is too high, you can lower it to

the specified value by opening the bleed valve of the fill-
ing device. Note that the bleed valve must be closed to
check the correct reading.
03.3.3.2 Note !
As the precharging pressure changes with the tempera-
ture, recheck the accumulator precharging pressure ap-
proximately 2 minutes after filling. Correct possible
deviations from the specified value.
Tighten the pressure accumulator shut-off screw to 25

Nm, and close the nitrogen gas bottle valve. Open the
bleed valve of the filling device to let out the gas in the fill-
ing device.

26 Hydraulic System
Remove the filling device, and check the shut-off valve for
tightness using, for example, soap liquid. Repair possible
leaks at once as it may cause damage to the pressure ac-
cumulator diaphragm. Seal the shut-off screw with seal-
ing lacquer and install the shut-off screw cap. The
pressure accumulator is now ready to be installed.
Warning!
Oxygen or air should never be used for precharging.
Danger of explosion!

Hydraulic System 27
03.4 Steering Hydraulic System

03.4.1 Steering System
Steering system has the following characteristics:
1. A defined amount of hydraulic oil passes from steering

device to the steering cylinder, whereby the wheels
turn according to the turning of the steering wheel.
2. The required steering power remains low in all cir-

cumtances.
3. The system incorporates no mechanical connections

between the steering wheel and the road wheels.
4. Load sensing.
In steering system with load sensing both load sensing

and working hydraulics pressure can be produced with a
common pump. Load sensing device have an extra con-
nection for load sensing (LS) so that the load sensing sig-
nals can be transferred from the steering device to the
priority valve. The LS connection is open directly into the
tank when steering is in the middle position. The structure
of the steering system is described on the following page.
The operation of the system is as follows:
When the steering wheel is turned, the inner rotary sleeve

(5) turns and shuts off free circulation of oil. It directs the
incoming oil to the other side of the metering pump, de-
pending on the turning direction of the steering wheel. As
the metering pump has a constant flow volume, the rota-
tor (1) makes it possible to have a precise amount of oil
flow to the steering cylinder. The rotator is mechanically
connected to the outer rotary sleeve (6), whereby the
turning of the rotator also moves the rotary sleeve.
The rotary sleeve shuts off the oil flow to the metering
pump, when the rotator has turned the same amount as
the steering wheel. Thus, the amount of oil corresponding
to the turning of the steering wheel can be accurately de-
termined. Steering responds already to a relative small
turning of the steering wheel, corresponding to a 2° to end
from turning rotary sleeve.
When this turning is 6° as an average, the valve is com-

pletely open. The turning of the rotary sleeves is mechan-
ically restricted in both directions to an average of 8° from
the middle position. The oil returning from the steering
cylinders is directed through the tank channel back into
the tank.

28 Hydraulic System
03.4.2 Steering Device
Figure 8. Steering Device
1 Rotor
2 Centering springs
3 Body
4 Ball-valve
5 Inner control spool
6 Outer control spool
7 Drive-shaft
8 Stator
LS Load-sensing-line

Hydraulic System 29
03.4.3 Oil Flow in Load Sensing Steering

System
Figure 9. Load Sensing Steering System
A Middle position - Oil flow situation
B Steering right - Oil flow
1 Oil to priority valve
2 Oil to steering divice

3 Oil in load sensing line
4 Oil in steering cylinder
5 Oil not flowing

30 Hydraulic System
6 Oil to working hydraulics
7 Oil to tank connection
8 Oil in intake pipe line

9 Load sensing LS-line connected to tank
03.4.4 Fault Diagnosis

Possible disturbances in steering system operation, and
instructions for their removal.
1. Slow steering
a) Overpressure valve or steering device ball partly

open because of dirt and causing constant bypass flow
of oil.
b) Clamped pressure hose resticking oil flow.
2. Lack of steering power
a) Insufficient amount of oil in tank, due to leaking.
b) As in 1a above.
3. Jerky or sticky steering
a) Clamped hose causing overpressure in return side.
4. Motoric operation (self-steering)
a) Dirt in oil causing steering device rotary sleeves to

stick. Clean the system troughly and fill with new clean
oil.

Hydraulic System 31
03.5 Hydraulic Components for Basic

Machine
18
32 1
36
PM2 PM1
16
29
27
PM5 30
37
31, PM8 26, PM4 PM3 17 15
Figure 10. Hydraulic Components for Basic Machine
1 Hydraulic oil tank

15 Return filter
16 Pumps
17 Pumps
18 Oil cooler
27 Priority valve
26 Directional control valve
29 Pressure accumulator
30 Directional control valve M400LS
31 Pressure reducing valve
32 Pressure release- free circulation valve
36 Directional control valve, miniratti (optional)
37 Pressure filtres (optional)
PM Pressure measuring

32 Hydraulic System
03.5.1 Hydraulic Oil Tank Maintenance Points
4
2
3 1 8 11
10
5 6 7
Figure 11. Hydraulic Oil Tank Maintenance Points
1 Hydraulic oil return filter

2 Magnet rod. Clean when change filter
3 Hydraulic oil filling cap. Do not open plug when the engine is
running
4 Hydraulic oil tank breather
5 Sight glass/ oil temperature
6 Hydraulic oil tank draining plug
7 Brake hydraulic oil tank draining plug
8 Brake hydraulic oil filling cap
9 Filter indicator, hydraulic system (S239A)
10 Hydraulic oil cooler
11 Brake hydraulic oil cooler
12 Filter indicator, brake system (S239B)

Hydraulic System 33
Warning!
Do not open the plug when the engine is running!
Hydraulic oil level is correct when it is between the
min. and max. lines. Retract the telescope and lower
the boom before checking hydraulic oil level.

34 Hydraulic System
03.5.2 Pumps
16.1
17.1
PM1
16.2
17.2
17.3
PM2 PM3
Figure 12. Pumps

16.2 Steering, lift and boom in/out
17.2 Spreader and fast lifting
17.3 Brakes
PM1 Pressure measurement

Hydraulic System 35
03.5.2.1 Adjusting Pressure of Adjustable

Displacement Pump
1. Connect a pressure gauge to pressure measurement
point (PM) of pump to be adjusted.
2. Open safety valve A.
3. Twist stand-by controller B closed.
4. Start the engine.
5. Twist safety valve A to requested adjustment value.
Open stand-by controller B, until yo reach the correct ad-

justment value, 30 bar.
Figure 13. Adjustable Displacement Pump

36 Hydraulic System
03.6 Hydraulic Components for the

Cabin Transfer
S97A,S97B 1
S97b
3 N
Y96a Y96b
2
Pm1 A Rv
B S296 S297
5
4
Figure 14. Hydraulic Components of the Cabin Transfer
Pm1 Pressure measuring

Rv Relief valve
S97a Cabin transfer forwards
S97b Cabin transfer backwards
S296 Cabin transfer forwards
S297 Cabin transfer backwards
S97A,S97B Inductive limit switchs for cabin transfer
1 Cabin transfer cylinder
2 Locking valve
4 Pump and tank
5 Filling, V=2.8L

Hydraulic System 37
03.6.1 Pressure Adjusting for the Load Control

Valve
1. Open locking anticlockwise.
2. Turn the adjusting screw (5) fully closed anticlocwise.
3. Adjust 3 turns clockwise.
4. Lock the adjusting screw (5).
Working pressure for cabin movements:
Forward Pm1 ≈ 90bar
Rearward Pm1 ≈ 40bar
03.6.2 Pressure Relief Valve (Rv) Adjusting

1. Connect the pressure gauge (min.150bar) to the
measuring point Pm1.
2. Take off the sockets (6) from the directional valve.
3. Adjust pressure to 120bar.
4. Take off the pressure gauge and put the sockets on.

38 Hydraulic System
60 60 6
96a 96b
Pm1
120
Rv
5 Rv
Figure 15. Hydraulic Schema of the Cabin Transfer
Pm1 Pressure measuring

Rv Relief valve
1 Cabin transfer hydraulic cylinder
2 Locking valve
4 Pump unit
5 Adjusting screw
6 Socket

Hydraulic System 39
03.6.3 Oil Changing to the Cabin Transfer

Hydraulic
1. Move the cabin to the rear position (the cylinder full
stroke in).
2. Open the pipe (A) from the pressure side of the pump
and drain the tank by using the
pump carefully.
Warning!
Do not use the pump without oil in any circumstanc-
es!
3. Plug the pipe (A) from the pressure side of the pump
and fill the tank (2,8l) through filling
cap (5).
4. Move the cabin forwards and backwards 1-2 times and

check oil quantity.

40 Hydraulic System
03.7 Hydraulic Components for the

Spreader
Figure 16. Hydraulic Components for the Spreader
1.1 1.2 Cylinders for sideshifting

2.1 2.2 Cylinders for spreader lengthening/shortening
3.1 3.2 Cylinders for twistlocks
4.1 Valve for sideshifting
4.2 4.3 4.4 Valve block for twistlocks and spreader lengthening/
shortening
32.1 32.2 Counterbalance valves of twistlocks

Hydraulic System 41
03.7.1 Adjusting the Spreader Lengthening
4.2 4.3
4.4
1
Figure 17. Valves of Spreader Lengthening / Shortening
and Twistlocks
1 Adjust screw
33.1 Locking valve, left
33.2 Locking valve, right
4.2 Spreader lengthening/shortening, left
4.3 Spreader lengthening/shortening, right
4.4 Twistlocks
PM41 Pressure measuring
PM33 Pressure measuring
Counterbalance Valves Setting (100bar) :

- Open locking anticlockwise.
- Turn screw fully open anticlockwise. (1)
- Adjust 3 turns clockwise. (1)
- Lock the adjust screw.
Locking valve (33.1, 33.2) opening pressure after adjust-

ing is 100bar.
Pilot ratio is 3:1

42 Hydraulic System

Electric Systems 1
04 Electric Systems
04.1 Electrical System General ................................................................ 2
04.1.1 Safety ...................................................................................... 2
04.2 Maintenance of Electric System ...................................................... 3

04.2.1 Batteries .................................................................................. 3
04.2.2 Alternator ................................................................................ 4
04.2.3 Welding Machine .................................................................... 5
04.2.4 Locating Electric Faults ........................................................... 6
04.2.5 Electric Diagram's Reading Order .......................................... 7
04.3 Reach Stacker's CAN-based Control System ................................ 8

04.3.1 System Structure .................................................................... 8
04.3.2 Multi-function Display A80 .................................................... 11
04.3.3 Alarms ................................................................................... 16
04.3.4 Tests ..................................................................................... 18
04.3.5 Control Module A81 .............................................................. 20
04.3.6 Control Module A82 .............................................................. 23
04.3.7 Control Module A83 .............................................................. 26
04.3.8 Control Module A84 .............................................................. 29
04.3.9 Engine Control ...................................................................... 31
04.3.10 Control of Boom and Spreader ........................................... 35
04.3.11 Monitoring of Stability ......................................................... 46
04.3.12 Load Weighing .................................................................... 46
04.3.13 Calibrations ......................................................................... 48
04.3.14 Functions of By-pass and Emergency Switches ................. 55
04.3.15 Bus Errors ........................................................................... 56
04.3.16 Replacement of a Module ................................................... 58
04.4 Electric Equipment for the Power Unit Scania DI12 EDC/PDE ... 59
04.5 Electric Equipment for the Power Unit .......................................... 60
04.6 Electrical Equipment in the Frame ................................................ 61

2 Electric Systems
04.1 Electrical System General

The nominal voltage of the electric system is 24 VDC.
The electric system follows the 1-conductor principle,
where the frame acts as the other conductor.
To make detecting of possible malfunctions and trouble-

shooting easier, all leads are numbered according to the
markings specified in the electric diagrams.
04.1.1 Safety
The insulation material of the conductors is oil resistant.
Wiring may not, however, be in contact with oils or other
solvent fluids.
Close to the engine and other hot surfaces, make sure

that the cable insulations are not damaged of the heat.
Replace cables with damaged insulations immediately.
Warning!
Blowing of a fuse always indicates a fault in the elec-
tric system. Repalr the fault prior to fitting a new fuse.
Warning!
The new fuse must absolutely have the same specifi-
cation as the previous one!
The size and locations of fuses are specified in the wiring

diagram.
Warning!
The control and alarm system of the machine pro-
tects it and gives warnings to the driver and the envi-
ronment. Don't make any alterations in the electric
system without manufacturer's permission.
The alterations in the electric system may deteriorate

the safety of the machine and will release the manu-
facturer from all warranty liabilities.

Electric Systems 3
04.2 Maintenance of Electric System

04.2.1 Batteries
G1
Figure 1. Batteries
The 24V electric system of the stacker is provided with

two 12V lead-acid batteries connected in series. Regular
maintenance of the batteries lengthens their life.
04.2.1.1 Checking and Service Instructions for

Batteries:
• Check that the batteries are properly fastened in their
mountings.
• Keep the outside of the batteries clean.
• Clean away possible dirt and oxidation from the bat-

tery terminal connections.
• When connecting the cable lugs to the battery termi-

nals, observe that the positive cable is always con-
nected to the positive terminal. Incorrect connecting
damages the battery and the electric equipment.
Connect the negative (frame) cable to the negative
battery terminal after connecting the positive cable.
• When connecting the cable lugs, take care not dam-

age the battery terminals or the lugs, which are made
of soft material. After connecting, smear the cable with
protective grease
• Check the electrolyte level in the battery cells at 250 h

intervals. The level should be approx. 1 cm above the
plates. Check also that the vent holes in the battery
caps are clear.
• Use a hydrometer to check the state of charge of the

battery, if the electric system of the machine has mal-
functions. The specific gravity of the electrolyte in a ful-

4 Electric Systems
ly charged battery is approx. 1.280 and approx. 1.150

in a partially charged battery.
If the specific gravity of the electrolyte is approx. 1.150
it will freeze at approx. -10°C.
Warning!
Do not leave a partially charged battery where it may
freeze.
04.2.2 Alternator
Figure 2. Alternator
An alternator has been chosen to supply the electrical en-

ergy due to its long life and small need for service. The
bearing houses are sealed and they should be repacked
with grease only at major overhauls.
Due to the construction of the alternator the following pre-

cautions must be kept in mind, since severe damage
might be otherwise caused to the electrical equipment.

Electric Systems 5
04.2.2.1 Warnings
• When connecting the battery to the circuit, always
make sure that the battery and the alternator are
grounded by terminals of same polarity.
• Never short circuit or ground the terminals of the alter-

nator or the regulator.
• Never run the alternator at "no load" and therefore

make sure all connections are clean and tight.
• When the battery is in the circuit and you have to con-

nect a charger to the circuit, make sure that terminals
of similar polarity are connected.
• Do not switch off the main electrical switch with engine

running.
• When repairing the vehicle by electric welding, all al-

ternator and regulator terminals must be disconnect-
ed.
Warning!
Repairs and adjustments of the alternator and the
regulator should only be carried out by professional
personnel.
04.2.3 Welding Machine

Before starting to weld:
• Disconnect the negative battery cable from frame.
• Disconnect the alternator cables at their terminals on

the alternator.
• Disconnect the electronic control modul of engine.
• Connect the ground cable of the welding machine as

close to the welding point as possible. This is prevent
the welding current from flowing through and damag-
ing the bearing surfaces of parts and components.

6 Electric Systems
04.2.4 Locating Electric Faults

Check the fuse if an electric function of the machine is not
working. If the fuse is not blown, check the circuit of the
function with the aid of the wiring diagram.
If the fuse is blown, turn all electric switches open, and re-
place the blown fuse with a new one of the same amper-
age. Switch the electric functions on one by one to
determine which of the functions causes the fuse to blow.
When the fault has been located, switch off the machine's
electric circuit with the main switch or the ignition key
while carrying out the repairs.
If the fault is in the starter motor or alternator circuits, dis-

connect the negative cable between the battery and the
frame while carrying out the repairs.
Warning!
When the machine is used, the frame cables of the
cabin, the engine, and the frame structures must be
connected. Insufficient ground connections cause
fire hazards !

Electric Systems 7
04.2.5 Electric Diagram's Reading Order
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Nimi Piirustus n:o Muutos Lehti

Title
El. schema Drawing n:o Rev. Sheet
T˜ T˜ ASIAKIRJAA EI SAA ILMAN SUOSTUMUSTAMME KOPIOIDA, ESITT˜ ˜

TAI LUOVUTTAA KOLMANNELLE HENKIL LLE EIK˜ K˜ YTT˜ ˜ MUIHIN KUIN
MEID˜ N SALLIMIIMME TARKOITUKSIIN
IT IS FORBIDDEN TO COPY THIS DOCUMENT OR REPRODUCE IT OR SURREND -
ER IT TO A THIRD PARTY. IT MUST NOT BE USED FOR ANY OTHER
PURPOSES THAN THOSE APPROVED BY US.
T5656860 16
Muutosehdotuksista on heti ilmoitettava piirustuskonttoriin.
Figure 3. Electric Diagram’s Reading Order
1 Page number of electric diagram

2 Drawing number of electic diagram
3 X-coordinate on the margin
4 Because there are no wire numbers on card, L3 is a line
edentification with a direct relation to the corresponding line
identifications on the next page.
5 Device identification
6 Connector number and pole number
7 Wire number
8 Pole number on the device
9 Y-coordinate on the margin
10 Wire continues on page 3 of the el. diagram, coordinate posi-
tion 27B.
11 Grounding on the frame

8 Electric Systems
04.3 Reach Stacker's CAN-based

Control System
04.3.1 System Structure
The system consists of control modules located in various
parts of the machine. They are located in accordance with
actuators or sensors, A81 in the frame's electric box, A82
and A84 in the cabin's electric box, A83 in the boom end
and display module A80 in the left dashboard. The mod-
ules are connected to each other with a CAN bus, through
which communication between the modules takes place.
(CAN=Controller Area Network) A display module is used
as the user interface. Each module has its own applica-
tion program.
*
A96 (ECU)
*
*
35
1 7
9 113
15 VASTUKSET
35
1 7
9 11 3
15
K19 K33 K17
46
2 18
0 12
14
16
9 40
8 41
7 182
46
2 18
0 12
14
16 +5V
REF OUTSY T T 1
4
37
1516
SUMMERI F1
F13 F1
4 F1
5
42
4 43 13
6
514
KIN 8 50 119
7
87
120
7 51
53
6 54
4
5 52 5 16
9
4 5
4
2
3
55
3 56
1
2 57 7 8
3
1
2
9
F1F1
8 F2
9 0 F2
F21
F2F2
6 F2 7 8 F3
F29 F3
0
F3
1 2F33
9 48
0 17
18 2 X44 XPO XR1 XSR
2
1
7 44
21 16
315 4
3 6
5 443
5
4 4 45 13 5
14
6 2
3 44
67 12 7
6
1 44
89 11 8
10 9 SX1 X191 XR2 XR3 XHR
9
8 50 8 1
9 2
7
6 12
55 7 43
6
1 5
4 53
54 5 6
4 5
3
2 3 55 X115 XKTS X22 X32 X37
2 56 3 7
2
4
5 1 57 1 98
6
7
XPC
A80
A84 A82 A81 A83
Figure 4. Location of modules and wiring of CAN-bus
Modules control functions of the machine as follows:
A81 Hydraulics module
• Boom lifting/lowering
• Lock valves of lowering
• Retardation of lowering
• Quick movement of lifting
• Βoom movements out/in
• Spreader rotation

Electric Systems 9
• Αdditional limits of spreader rotation

• Spreader indicator lights
• Cabin transfer
• Electric gas
• Coolant level
A82 Cabin module
• Monitoring of engine
• Monitoring of stability
• Automatic changer (option)
• Mini-steering wheel (option)
• Load display (option)
• Pressure weighing, (option)
• Vertical lifting/lowering (option)
• Idling stop (option)
A83 Spreader module
• Spreader rotation
• Limits of rotation
• Spreader extension/shortening
• Tilting forward/backward
• Locking of tilting
• Sideshift
• Automatic gripping of spreader
• Movements of shafts manually
• Container contact
• End dampening of boom movements
• Spreader indicator lights
• Active tilting (option)
A84 Input module
Cabin's switch data has been collected to the input mod-

ule. (Module does not contain a program).
A80 Display module
• Driver's displays, gauges

• Alarms
• Error messages

10 Electric Systems
• Settings of functions
- Automatic gripping on/off
- Automatic changer on/off
• Μaintenance displays
• Calibrations
- Stability
- Gas pedal
- Load weighing
Maintenance personnel can see the statuses of module

outputs and inputs on the maintenance displays, so sep-
arate measurements are not needed. From the calibra-
tion displays you perform, depending on the options,
calibration of gas pedal, stability and load weighing.
04.3.1.1 General
When you switch on the power to the machine, the dis-
play will show the type of the machine (e.g. DRS4531-S5)
for 1 second. After this the display will show the basic dis-
play and you can start the machine. Displays vary accord-
ing to the options installed.
Stability 1
40 %
N
Stability 2
40 %
N 1.1 m 3.5 t
2
Figure 5. 1 = Basic display 2 = Basic display with

options

Electric Systems 11
04.3.2 Multi-function Display A80

Module-controlled functions of the machine are displayed
on a multi-function display. In normal operation the dis-
play shows a basic display, which is one of the ones be-
low depending on the options installed in the machine. In
addition to the driver's displays, there are also mainte-
nance and calibration displays, which are protected with
key switch S3 (located in the cabin's electric box). The
display also shows alarms reporting errors in the engine,
bus and sensors. See item Alarms.
Number and contents of displays depend on the options

installed in the machine. You can select a language ver-
sion for the display from 13 alternatives. If you select Eng-
lish USA, the units of measurement will change to those
used in the USA.
1
40 %
1F 1.1 m 3.5 t
2
3 4 5 6 7
Figure 6. Multi-function Display
1 1st line of display

2 2nd line of display
3 Change display to maintenance displays (only for professional
maintenance personnel)
4 Scrolling of displays
5 Return to driver's displays, to basic display
6 Container counter reset: press * key for two seconds (optional)
7 Automatic gripping on/off / Automatic gearshift on/off (optional)
04.3.2.1 Driver's Displays

There are 7-9 driver's displays, (depending on options)
which can be scrolled with the arrow keys.

12 Electric Systems
Driver's display 1, Basic display

line 1 Stability %
line 2 Gear and driving Spreader’s Load (option)

direction reach
(option) *
1 2 3 4 F = Forward m (ft) t (l.t.)

N = Neutral
1 2 3 4 R = Reversed
*) Horizontal distance from the centre of the drive axle to

the centre of the spreader.
Driver's display 2
line 1 Speed km/h (mph)
line 2 Slip ratio % engine/transmission
Driver's display 3
line 1 Engine rpm rotation speed of
engine
line 2 Gears rpm rotation speed of

transmission
Driver's display 4
line 1 Engine Water
line 2 °C (F) engine water temper-

ature
Driver's display 5
line 1 Engine oil
line 2 bar engine oil pressure
Driver's display 6
line 1 Operating hours
line 2 h h operating hours /

effective operating
hours
Driver's display 7
line 1 Containers Containers counter
(optional)
line 2
Container counter reset: press * key for two seconds.

Electric Systems 13
Driver's display 8
line 1 Autom. gripping
line 2 on/off automatic gripping

on / automatic grip-
ping off
on/off selecting with OK key
Driver's display 9
line 1 Autom. changer (option)
line 2 on/off automatic gearshift

on/off
on/off selecting with OK key
04.3.2.2 Maintenance Displays

Maintenance displays are only intended for professional
maintenance personnel, so they can correct error situa-
tions and make the necessary calibrations in connection
with repairs.
Move to maintenance displays by turning key switch S3

to the ON position and then pressing the M key once.
Select module to check with arrow keys: Module A81,

A82, A83 or A84. Use OK key to move to displays of the
selected module, and browse displays with arrow keys.
Module displays show: DI=digital inputs (1 or 0), A =ana-

log inputs (0,00…5,00V), DO =digital outputs (1 or 0) and
PR =proportional outputs (%).
In order to locate the error, values are compared to mod-

ule-specific reference values. (see Control module A80 -
A84).
Maintenance Display Module A81
line 1 Module A81 module 1
line 2 Can bus 1/0 bus in operation /

bus oout of order
Maintenance Display Module A81 Sub-display 1
line 1 DI 1234567890 digital input 1-12
line 2 0000000000 status of said input 1

or 0

14 Electric Systems

Analog input and its voltage value 0.0 ...5.00 V.
line 1 A1 0.00 A2 0.00
line 2 A3 0.00 A4 0.00

Analog input and its voltage value 0.0 ...5.00 V.
line 1 A5 0.00 A6 0.00
line 2 A7 0.00 A8 0.00
line 1 DO 123456789012 digital output 1-12
line 2 000000000000 status of said output

1 or 0

Value of propo outputs %.
line 1 PR1 0 PR2 0
line 2 PR3 0 PR4 0

line 1 PR5 0 PR6 0
line 2 PR7 0 PR8 0

line 1 PR9 0 PR10 0
Corresponding displays for modules A82 and A83.
Maintenance Display Module A84
line 1 Module A84 xxxx
line 2 Can bus 1/0 bus in operation /

bus out of order

Electric Systems 15
line 1 DI 123456789012 digital input 1-12
line 2 A 000000000000 status of said input 1

or 0
line 1 DI 345678 digital input A 13-18
line 2 A 000000 status of said input 1

or 0
line 1 DI 123456789012 digital input B 1-12
line 2 B 000000000000 status of said input 1

or 0
line 1 DI 345678 digital input B 13-18
line 2 B 000000 status of said input 1

or 0

16 Electric Systems
04.3.3 Alarms
Alarms are divided into alarms and critical alarms. The di-
vision is explained in the tables below.
04.3.3.1 Critical Alarm

When a critical fault appears, the display shows an alarm
text and the buzzer sounds twice for 1 second
(1s_1s_1s). When the driver has noticed the message,
he can return to the basic display with the OK button. The
alarm text will disappear from the display after a specified
time. If the reason for the error disappears, the message
will also disappear from the display.
If there are several alarms on the display at the same

time, the most critical will be topmost [P]. You can scroll
them with the arrow key. If alarms have been acknowl-
edged from the display with the OK button and there is a
new alarm, the already acknowledged alarms will also ap-
pear on the display if the errors have not been removed.
P Alarm Reason Consequence

1 LOAD PARAMETERS Parameters have not been loaded Movements controlled by modules
are forbidden
2 ERROR CAN ENGINE Breakdown in Can communication Lifting/lowering and boom out move-
or Emergency-button is pressed ments are forbidden, only permitted if
you press stability by-pass button S85
3 ERROR ENGINE Wrong engine type selected with Engine will start and stop but gas
parameter pedal will not work. Display shows
zero.
4 ERROR ENGINE 00000 QSM Engine error Fault code on display has to be
checked and done according that.
5 ENGINE WATER TOO HOT Temperature over set alarm limit Limit maximum power
6 ENGINE WATER TOO HOT Temperature has been over set limit Engine stalls, will not start
value for a specified amount of time
7 ENGINE OIL PRESSURE Oil pressure below set alarm limit Limit maximum power
LOW
8 ENGINE OIL PRESSURE Oil pressure has been below set Engine shut-off
LOW value for a specified amount of time
9 ERROR CAN A82 Breakdown in Can communication Lifting/lowering and boom out move-
ments are forbidden, only permitted if
12 ERROR R60 Sensor value is not within accepta- Boom movements permitted only by
ble limits. Calibration < 100mV pressing stability by-pass button S85.

Electric Systems 17
P Alarm Reason Consequence

13 ERROR R61 Sensor value is not within accepta- Boom movements permitted only by
ble limits. Calibration value < pressing stability by-pass button S85.
100mV
14 ERROR B6 Sensor value is not within accepta- Boom movements permitted only by
ble limits 0.1-4.9V. pressing stability by-pass button S85.
15 ERROR B8 Sensor value is not within accepta- Boom movements permitted only by
ble limits 0.1-4.9V. pressing stability by-pass button S85.
17 ERROR A312 Sensor value is not within accepta- Gas demand is 0% , engine is idling
ble limits 0.1-4.9V (during calibra-
tion 0.75-1.25V)
18 LOW BRAKE BRESSURE Low brake pressure when starting Driving direction cannot be selected
or driving
19 ERROR ENGINE TEMPERA- Engine error code on display Limit maximum power
TURE
20 ERROR OIL PRESSURE Engine error code on display Limit maximum power
21 ERROR ENGINE RPM Engine error code on display Limit maximum power
04.3.3.2 Non-critical Alarms

When an error appears, the display shows an alarm text
and the buzzer sounds once for 1 second. When the driv-
er has noticed the message, he can return to the basic
display with the OK button. The alarm text will disappear
from the display after a specified time. If the reason for the
error disappears, the message will also disappear from
the display.
If there are several alarms on the display at the same

time, the most critical will be topmost. You can scroll them
with the arrow key.
Alarm Reason Consequence

DIRECTION SELECTED, WILL You try to start with the direction Engine will not start until you select
NOT START selected direction into neutral
F/R SELECTED Direction forward and rearward are Engine will not start until you select
selected at the same time direction into neutral
IDLING, ENGINE WILL STALL Pedal and lever have not been Engine shut-off in 2 min
used for the specified idling alarm
time
IDLING, ENGINE WILL STALL Pedal and lever have not been Engine shut-off
used for the specified idling stop-
ping time
STEERING AXLE OVERLOAD Rear-axle is overloaded Lifting and boom in movements are for-
bidden, only permitted if you press sta-
bility by-pass button S85.
ENGINE UNDER-TEMPERATURE Temperature has been below the Check thermostat
set limit value for a specified
amount of time

18 Electric Systems
Alarm Reason Consequence

SHUT-OFF DELAY Option to stop after-running has Engine will only shut off after a time
been selected and the engine is specified by the parameter
shut off with the key
EMERGENCY STOP PRESSED S112 emergency stop switch has Engine shuts off, will not start until
been pressed switch has been released
HANDBRAKE Handbrake was pressed when Driving direction cannot be selected
starting
ENGINE WATER LEVEL TOO Engine water level too low
LOW
04.3.4 Tests
04.3.4.1 Tested During Operation

When the machine is operated, you should make sure
that counter-movements are not controlled simultaneous-
ly. Input voltage B6 and B8 of lifting cylinder's pressure
transmitters (right and left) must be greater than 0,1V and
smaller than 4,9V. Otherwise the display will show alarm:
ERROR B6 or ERROR B8, and boom movements are
only allowed by pressing stability by-pass button S85.
Steering axle loading is tested during operation, and if it
is overloaded the display will show alarm: STEERING
AXLE OVERLOAD.
Gas pedal voltage is monitored during use. The display

will show alarm ERROR A312 and request for gas will be
0% (idling), if voltage is 0,1V or smaller, or if voltage is
4,9V or greater, or if voltage is 25% smaller than calibrat-
ed minimum, or if voltage is 25% greater than calibrated
maximum. If voltage is between the 25% alarm mimit and
the calibration value, control will be according to minimum
or maximum. There will not be a gas pedal alarm from a
25% deviation, if the gas has not been calibrated.
When the emergency stop switch has been pressed, after

the half-second delay the display will show message
EMERGENCY STOP SWITCH PRESSED. If the ma-
chine was shut off from the emergency stop switch, it will
not start until you have lifted the "mushroom switch".
When A82_DI5 =0 (shut-off from key), there will be no
alarm. If handbrake is pressed and you try to move, the
display will show message HANDBRAKE and direction
solenoids will not go on until you disengage the hand-
brake. Also, if you get a handbrake alarm during driving,
direction solenoids go into neutral. When you start mov-
ing, brake pressure is checked, and if it is too low
(A84_DI13B=1), the display will show message LOW
BRAKE PRESSURE and direction solenoids will not go
on. Also, if you get a brake pressure alarm during driving,
direction solenoids will go into neutral.

Electric Systems 19
04.3.4.2 Testing of Stability Sensors

Values of boom's angle and length sensors and of lifting
cylinder's pressure transmitters (right+left) must be within
the acceptable range after calibration during operation.
Otherwise the display will show alarm: ERROR R60 or
ERROR R61. Then boom movements are only permitted
by pressing the by-pass button S85.
04.3.4.3 CAN Testing

If communication in the Can bus breaks down (monitored
constantly) lifting/lowering, telescope out movements will
be forbidden and the display will show message: ERROR
CAN Axx or ERROR CAN ENGINE. After the bus has re-
turned to normal, the alarm will disappear and the move-
ments are permitted. Bus error overrides short-circuit
error. S85 permits movements during the error, but then
stability monitoring will not operate reliably.
04.3.4.4 Engine Alarms

If you try to start the engine while direction forward or
rearward is selected, the display will show alarm DIREC-
TION SELECTED, WILL NOT START, and the engine
will start only after you select the direction into neutral. If
direction forward and rearward are selected at the same
time (mini wheel in use), the display will show alarm F/R
SELECTED.
If the engine has been idling for a certain time and the op-
tion has been selected, the display will show alarm
IDLING, ENGINE WILL STALL. The temperature of the
engine's coolant is monitored, and in an error situation the
display will show alarm ENGINE WATER TOO HOT or
ENGINE UNDERTEMPERATURE. If the oil pressure is
low while the engine is running, the display will show
alarm ENGINE OIL PRESSURE LOW. If engine water
level is too low (A81_DI1=1), the display will show alarm
ENGINE WATER LEVEL TOO LOW, alarm does not af-
fect operation of the machine in any way . If option to stop
after-running has been selected and the engine is shut off
with the key, the display will show alarm: SHUT-OFF DE-
LAY and engine will only shut off after a time. If there is a
sensor error the display will show alarm: ERROR EN-
GINE TEMPERATURE, ERROR OIL PRESSURE or ER-
ROR ENGINE RPM. If you have selected the wrong
engine type (Scania/Cummins) with a parameter, the dis-
play will show alarm ERROR ENGINE. Cummins engines
show an error code, which is displayed as ERROR EN-
GINE and error code.

20 Electric Systems
04.3.5 Control Module A81

A81 controls following functions: boom hoisting and low-
ering, lowering locking valves, quick function of hoisting,
boom out, boom in, spreader rotation and limits of
spreader rotation, spreader automatic gripping, spreader
signal lights, stability by-pass, el. gas, coolant level, pres-
sure weighing (optional).
155
137
DO12 151
DO11 152
+24VOut
PRO8
DO10
GND
GND
GND
DI12
DI11
DO9
DO8
DI3
DI4
DI5
DI6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
7
8
39
38
37
36
35
34
59
58
26
25
24
23
22
21
20
19
X3 X5
DI1 9 40 18 1 PRO7
DI2 8 41 17 2 GND
S99 S100 117 +24VOut 7 42 16 3 PRO6
GND 6 43 15 4 PRO5
X6
DI7 5 44 14 5 DO7 165 Y96A
S100 114 DI8 4 45 X1 13 6 DO6 166 Y96B
S79 113 DI9 12 7
5
6
3 46 GND
DI10 2 47 11 8 DO5 M97
AI8 1 48 CONTROL UNIT 10 9 DO4
A312 129 AI7 9 49 9 1 PRO4 171 Y57
R58 128 AI6 8 50 A81 8 2 GND
R58 127 AI5 7 51 7 3 PRO3 173 Y52
R53 126 AI4 6 52 6 4 DO3 174 Y87
R54 125 AI3 5 53 X2 X7 5 5 PRO2 175 Y58
124 AGND 4 54 4 6 DO2 176 Y67, Y68
R52 123 AI2 3 55 3 7 GND
R51 122 AI1 2 56 2 8 PRO1 178 Y51
121 RefOut 1 57 1 9 DO1 179 Y56
X4 X8
27
28
29
30
31
32
33
60
61
62
63
64
65
6
5
4
7
6
5
4
3
2
1
3
2
1
CAN Shield
WH CAN High
CAN Low
PRO10
PRO9
GND
GND GND
GND
GND
VCC
VCC
RxD
TxD
BN
Figure 7. Control Module A81
Note! When checking the reference values, the engine

must not be running.
Connector Code Function Rating Wire no. Note

X1.1 AI8
X1.2 DI10 Jacks down
X1.3 DI9 Scaling position angle 0V off, +24V on 113 S79
X1.4 DI8 Rotation extra limits in use 0V off, +24V on 114 S100
X1.5 DI7

Electric Systems 21

X1.6 GND
X1.7 +24V out +24V 117 S79/
100
X1.8 DI2
X1.9 DI1 Coolant level 0V off, +24V on
X2.1 Refout Ref. out, Hand lever feed +5VDC 121
X2.2 AI1 Boom lifting 0V...5V 122 R51
X2.3 AI2 Boom lowering 0V...5V 123 R52
X2.4 AGND 124
X2.5 AI3 Boom in 0V...5V 125 R54
X2.6 AI4 Boom out 0V...5V 126 R53
X2.7 AI5 Rotation counter-clockwise 0V...5V 127 R58
X2.8 AI6 Rotation clockwise 0V...5V 128 R58
X2.9 AI7 El. gas accelerator pedal 0V...5V 129 A312
X3.1 DI3
X3.2 DI4
X3.3 GND
X3.4 +24 +24V out
X3.5 DI5
X3.6 DI6
X3.7 DI12 Stability By-pass 0V off, +24V on 137 S85
X3.8 DI11
X4.1 CAN CAN shield
X4.2 CAN CAN Low BN
X4.3 CAN CAN High WH
X4.4 VCC
X4.5 VCC Feed voltage +24V F38
X4.6 GND Earthing rail
X4.7 GND
X5.1 DO12 Twistlocks open information +24V 10W max 151 H180
X5.2 DO11 Twistlocks closed information +24V 10W max 152 H191
X5.3 GND
X5.4 DO10
X5.5 DO9 Container contact information +24V 10W max 155 H195
X5.6 DO8
X5.7 GND
X5.8 PRO8
X6.1 PRO7
X6.2 GND
X6.3 PRO6
X6.4 PRO5
X6.5 DO7 Cabin forward +24V 165 Y96A

22 Electric Systems

X6.6 DO6 Cabin rearward +24V 166 Y96B
X6.7 GND
X6.8 DO5 Cabin transfer pump 168 M97
X6.9 DO4
X7.1 PRO4 Boom lowering 171 Y57
X7.2 GND
X7.3 PRO3 Boom in 173 Y52
X7.4 DO3 Lifting quick function +24V 174 Y87
X7.5 PRO2 Boom lifting 175 Y58
X7.6 DO2 Locks of lowering 176 Y67,
Y68
X7.7 GND
X7.8 PRO1 Boom out 178 Y51
X7.9 DO1 Free circulation valve 179 Y56
X8.1 GND
X8.2 PRO10
X8.3 PRO9
X8.4 GND
X8.5 TxD
X8.6 RxD

Electric Systems 23

A82 controls following functions: engine control, stability,
automatic gearshift system (optional), mini steering
wheel (optional), display of the load (optio), vertical lifting
and lowering (optional), idling shut-off (option).
231
232
236
235
237
238
234
+24VOut
PRO8
DO12
DO10
DO11
GND
GND
DO9
GND
DI12
DO8
DI11
DI3
DI6
DI4
DI5
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
58
26
25
24
23
22
21
20
19
38
37
36
35
34
59
39
X3 X5
S2 219 DI1 9 40 18 1 PRO7
B1 218 DI2 8 41 17 2 GND
+24VOut 7 42 16 3 PRO6 263 Y27 B
BN GND 6 43 15 4 PRO5 264 Y27 A
A32 215 DI7
X6 265
5 44 14 5 DO7
A32 214 DI8 4 45 X1 13 6 DO6
S56 213 DI9 3 46 12 7 GND
S56 212 DI10 2 47 11 8 DO5 268 H13B
A312 211 AI8 1 48 CONTROL UNIT 10 9 DO4
R61 229 AI7 9 49 9 1 PRO4 271 K2
A82 8
R60 228 AI6 8 50 2 GND
B6 227 AI5 7 51 7 3 PRO3 273 Y4
B8 226 AI4 6 52 6 4 DO3 274 Y5
225 AI3 5 53 X2 X7 5 5 PRO2 275 Y3
224 AGND 4 54 4 6 DO2 276 Y2
AI2 3 55 3 7 GND
AI1 2 56 2 8 PRO1 278 S6
221 RefOut 1 57 1 9 DO1 279 Y1
X4 X8
60
61
62
63
64
65
28
29
30
31
32
33
27
7
6
5
4
3
2
1
6
5
4
3
2
1
CAN Shield
CAN High
CAN Low
PRO10
PRO9
GND
GND
GND
GND GND
VCC
VCC
RxD
TxD
WH
FI6
FI6
BN


X1.1 AI8 Electric gas accelerator pedal 211 A312
X1.2 DI10 Direction Reverse 212 S56
X1.3 DI9 Direction Forward 213 S56
X1.4 DI8 Mini steering wheel 214 A32
X1.5 DI7 Mini steering wheel 215 A32
X1.6 GND BN
X1.7 +24V out +24V

24 Electric Systems

X1.8 DI2 Transmission operating speed 218 B1
X1.9 DI1 Start 219 S2
X2.1 Refout Ref. out +5VDC 221
X2.2 AI1
X2.3 AI2
X2.4 AGND 224
X2.5 AI3 Stability sensor lift 0V...5V 225 A85
X2.6 AI4 Pressure of cylinder, left 0V...5V 226 B8
X2.7 AI5 Pressure of cylinder, right 0V...5V 227 B6
X2.8 AI6 Sensor of boom angle 0V...5V 228 R60
X2.9 AI7 Sensor of boom length 0V...5V 229 R61
X3.1 DI3 2 speed 231 S56
X3.2 DI4 3 speed 232 S56
X3.3 GND
X3.4 +24 +24V out +24V 234
X3.5 DI5 Engine stop, option 0V off, +24V on 235 S2
X3.6 DI6 1 speed 0V off, +24V on 236 S56
X3.7 DI12 Declutch 0V off, +24V on 237 S52
X3.8 DI11 Service Switch 0V off, +24V on 238 S3
X4.1 CAN CAN shield
X4.2 CAN CAN Low BN
X4.4 VCC F16
X4.5 VCC Feed voltage +24V F16
X4.6 GND Earthing rail
X4.7 GND
X5.1 DO12
X5.2 DO11
X5.3 GND
X5.4 DO10 Machine speed < 10 km/h
X5.5 DO9 Neutral speed
X5.6 DO8
X5.7 GND
X5.8 PRO8
X6.1 PRO7
X6.2 GND
X6.3 PRO6 Mini steering wheel 263 Y27B
X6.4 PRO5 Mini steering wheel 264 Y27A
X6.5 DO7 Shut-off delay 265
X6.6 DO6
X6.7 GND
X6.8 DO5 Buzzer 268 H13B

Electric Systems 25

X6.9 DO4
X7.1 PRO4 Start relay 271 K2
X7.2 GND
X7.3 PRO3 Direction Reverse 273 Y4
X7.4 DO3 3 speed 274 Y5
X7.5 PRO2 Direction Forward 275 Y3
X7.6 DO2 2 speed 276 Y2
X7.7 GND
X7.8 PRO1 Engine Start/Stop 278 S6
X7.9 DO1 1 speed 279 Y1
X8.1 GND
X8.2 PRO10
X8.3 PRO9
X8.4 GND
X8.5 TxD
X8.6 RxD

26 Electric Systems

A83 controls following functions of spreader and boom :
spreader rotation, limits of spreader rotation, spreader
lengthening/shortening, tilting forward/rearward, locking
of tilting, sideshift, twistlocks functions, container contact,
damping of telescope.


X1.1 AI8
X1.2 DI10 Stop, rotation counter-clockwise 0V off, +24V on 312 S99
X1.3 DI9 Stop, rotation clockwise 0V off, +24V on 313 S98
X1.4 DI8 Twistlocks open 0V off, +24V on 314 S121
S122
X1.5 DI7 Twistlocks closed 0V off, +24V on 315 S123
S124

Electric Systems 27

X1.6 GND
X1.7 +24V out +24V 317
X1.8 DI2 Landing pin right 0V off, +24V on 318 S127
S128
X1.9 DI1 Landing pin, left 0V off, +24V on 319 S125
S126
X2.1 Refout Ref. out +5VDC
X2.2 AI1 Limit, rotation counter-clockwise 0V...5V 322 S99B
(option)
X2.3 AI2 Limit, rotation clockwise limit 0V...5V 323 S98B
(option)
X2.4 AGND
X2.5 AI3
X2.6 AI4
X2.7 AI5
X2.8 AI6
X2.9 AI7
X3.1 DI3 20" - 40", right 0V off, +24V on 331 S136
X3.2 DI4 30" , right 0V off, +24V on 332 S236
X3.3 GND
X3.4 +24 +24V out +24V 334
X3.5 DI5 20" - 40", left 0V off, +24V on 335 S135
X3.6 DI6 30", left 0V off, +24V on 336 S235
X3.7 DI12 Boom out, damping 0V off, +24V on 337 S81
X3.8 DI11 Boom in, damping 0V off, +24V on 338 S80
X4.1 CAN CAN shield
X4.2 CAN CAN Low BN
X4.4 VCC
X4.5 VCC Supply voltage +24V F36
X4.6 GND
X4.7 GND
X5.1 DO12 Pile slope locking 351 Y66
X5.2 DO11 Pile slope to right 352 Y64A
X5.3 GND
X5.4 DO10 Twistlocks open light 354 H304
X5.5 DO9 Twistlocks closed light 355 H303
X5.6 DO8 Landing pin 356 H305
X5.7 GND
X5.8 PRO8 Pile slope to left 358 Y64B
X6.1 PRO7 Longit. tilting locking 361 Y63
X6.2 GND
X6.3 PRO6 Rotation counter-clockwise 363 Y59A

28 Electric Systems

X6.4 PRO5 Rotation clockwise 364 Y59B
X6.5 DO7 Sideshift left 365 Y62A
X6.6 DO6 Sideshift right 366 Y62B
X6.7 GND
X6.8 DO5 Longit. tilting forward 368 Y65A
X6.9 DO4 Longit. tilting rearward 369 Y65B
X7.1 PRO4
X7.2 GND
X7.3 PRO3 Twistlocks open 373 Y71A
X7.4 DO3 Twistlocks closed 374 Y71B
X7.5 PRO2 20”-40”, right 375 Y73A
X7.6 DO2 40”-20”, right 376 Y73B
X7.7 GND
X7.8 PRO1 20”-40”, left 378 Y74A
X7.9 DO1 40”-20”, left 379 Y74B
X8.1 GND
X8.2 PRO10
X8.3 PRO9
X8.4 GND
X8.5 TxD
X8.6 RxD

Electric Systems 29

Module A84 is an input module from different switches in
cabin.
INPUT B INPUT A
478 24V out 8 1 24V out 421
S112 477 DI1 7 2 DI1 422 S89
S58 476 DI2 6 3 DI2 423 S90
S97 475 DI3 5 4 DI3 424 S99
S97 474 DI4 4 5 DI4 425 S86
S192 473 DI5 3 X7 X2 6 DI5 426 S95
S251 472 DI6 2 MCKC-MODULE 7 DI6 427 S180
S251 471 DI7 1 8 DI7 428 S92
S71 468 DI8 8 A84 1 DI8 411 S192
S72 467 DI9 7 2 DI9 412 S237
S68 466 DI10 6 3 DI10 413 S194
465 DI11 5 4 DI11 414 S189
S23 464 DI12 4
X6 X1 5 DI12 415 S193
S13 463 DI13 3 6 DI13 416 S193
S199 462 DI14 2 7 DI14 417 S191
S115 461 DI15 1 8 DI15 418 S191
X5 X4
7
6
5
4
3
2
1
6
5
4
3
2
1
CANLO
CANLO
CANHI
CANHI
24Vout
+VCC
-GND
DI16
DI17
DI18
DI18
DI17
DI16
457
456
455
454
453
453
452
Pink
F16
WH
WH
BN
S990, S980
S97A-B S7
S97A
S97B
S60
S7

X1.1 DI8 Twistlocks closed, manual 0 V off, +24 V on 411 S192
X1.2 DI9 Spreader 30' position 0 V off, +24 V on 412 S237
X1.3 DI10 Hoist prevent by-pass 0 V off, +24 V on 413 S194
X1.4 DI11 Spreader autom. lenghtening 0 V off, +24 V on 414 S189
X1.5 DI12 Spreader lengthening, right T-balk 0 V off, +24 V on 415 S193
X1.6 DI13 Spreader shortening, right T-balk 0 V off, +24 V on 416 S193
X1.7 DI14 Spreader shortening, left T-balk 0 V off, +24 V on 417 S191
X1.8 DI15 Spreader shortening, right T-balk 0 V off, +24 V on 418 S191
X2.1 Refout Ref. output +24 VDC , max 2 A 421
X2.2 DI1 Side shift, right 0 V off, +24 V on 422 S89
X2.3 DI2 Side shift, left 0 V off, +24 V on 423 S90
X2.4 DI3 Hand lever change button/vertical lift 0 V off, +24 V on 424 S99
X2.5 DI4 Spreader lenghtening/ tilting forward 0 V off, +24 V on 425 S86
X2.6 DI5 Spreader shortening/ tilting rearward 0 V off, +24 V on 426 S95
X2.7 DI6 Twistlocks open 0 V off, +24 V on 427 S180
X2.8 DI7 Spreader tilt locking 0 V off, +24 V on 428 S92
X4.2 CAN CAN Low BN
X4.3 CAN CAN High Pink
X4.4 CAN CAN Low WH

30 Electric Systems

X4.5 GND GND Earthing rail
X4.6 +VCC Feed voltage F16
X5.1 Refout Ref. output +24 VDC , max 2 A 451 S97A-B
S7
X5.2 DI16 Cabin rearward, limit 0 V off, +24 V on 452 S97B
X5.3 DI17 Cabin forward, limit 0 V off, +24 V on 453 S97A
X5.4 DI18 Pile slope locking 0 V off, +24 V on 454 S60
(option)
X5.5 DI18 Door switch 0 V off, +24 V on 455 S990,
S980
X5.6 DI17 Seat switch 0 V off, +24 V on 456 S7
X5.7 DI16 Rotation speed range 0 V off, +24 V on 457 (option)
X6.1 DI15 Rotation limit by-pass 0 V off, +24 V on 461 S115
X6.2 DI14 Container contact by-pass 0 V off, +24 V on 462 S199
X6.3 DI13 Brake pressure, 115 Bar 0 V off, +24 V on 463 S13
X6.4 DI12 Brake information, 2,5 Bar 0 V off, +24 V on 464 S23
X6.5 DI11 Buzzer on 0 V off, +24 V on 465
X6.6 DI10 Speed locking 0 V off, +24 V on 466 S68
(option)
X6.7 DI9 Starting gear 0 V off, +24 V on 467 S72
(option)
X6.8 DI8 Automatic gear shift on/off 0V off, +24V 0 V off, +24 V on 468 S71
on 468 S71 (option)
X7.1 DI7 Jacks up 0 V off, +24 V on 471 S251
(optio)
X7.2 DI6 Jacks down 0 V off, +24 V on 472 S251
(option)
X7.3 DI5 Automatic gripping, on 0 V off, +24 V on 473 S192
(option)
X7.4 DI4 Cabin transfer, rearward 0 V off, +24 V on 474 S97
X7.5 DI3 Cabin transfer, forward 0 V off, +24 V on 475 S97
X7.6 DI2 Parking brake 0 V off, +24 V on 476 S58
X7.7 DI1 Emergency stop switch 0 V off, +24 V on 477 S112
X7.8 Refout Ref. output +24 VDC , max 2 A 478

Electric Systems 31
04.3.9 Engine Control

The engine is controlled by an ECU (Engine Control Unit).
The ECU is connected to the CAN bus, and control mod-
ule A82 carries out communication with it. Control module
A82 reads the position of the gas pedal and transmits it to
the ECU. A82 also performs starting and stopping of the
engine. ECU transmits several messages, which contain
information about engine status. Control module A82 re-
ceives and interprets these messages.
04.3.9.1 Starting the Engine

Switch on power to the engine A82:DI1 Æ 1 and set
A82:PRO1 (control 100%)
Upon starting there are safety checks made to make sure

that the engine will start safely.
- Direction forward A82 DI9 or rearward A82 DI10 must

not be selected. If direction is selected, the display will
show alarm: DIRECTION SELECTED, WILL NOT
START.
- Temperature of the engine coolant must be within the

acceptable range, otherwise the display will show error
message: ENGINE WATER TOO HOT.
- If ECU falls out of the bus, starting is forbidden.
When the above conditions are met, activate A82:PRO4

to set the starter motor on. If one of the above conditions
is not met during start, A82:PRO1 ja PRO4 will be reset.
Starter motor will be on as long as the engine rpm value

is below a limit value. While starting boom movements
and spreader rotation are forbidden.
When the rpm limit is reached, starter motor A82:PRO4

will be deactivated (control 0%), operating hour counter
will be activated and oil pressure will be monitored. If the
engine stalls, re-start will not begin until rpm is 0.
04.3.9.2 Stopping the Engine

Normal stopping by turning the key:- A82:DI5 Æ 0, oper-
ating hour counter is deactivated and A82:PRO1 deacti-
vated.
- If you have selected idling option, the display will show
message SHUT-OFF DELAY and the engine will be shut
off after delay once the key has been turned.
If you stop the engine in any other way than the usual
turning of the key, the display will show an alarm before

32 Electric Systems
the engine stops. The engine is stopped, if one of the fol-

lowing is true: A82:DI5 Æ 0
- Idling option, engine is shut off after delay from turning

of key and the display immediately shows message:
SHUT-OFF DELAY. If operation has been selected, it will
be activated for the specified time, when rpm is over
400rpm and A82_DI5=1 and A82_PRO1=100% and
A82_DO7=0. Operation: DO7 goes on, when DI5=0 and
for specified time PRO1 is 100%. During operation gas is
forbidden. Shut-off: PRO1=0% for 3 seconds, and after
that DO7=0 and PRO1=100%. Operation is reset imme-
diately, if DI5=1. Re-start is not possible (A82_PRO4)
during operation.
- Engine idling stop: gas pedal and lever have not been
used, the engine has been idling for a certain time, and
the handbrake is on. After a warning delay the display will
show: IDLING, ENGINE WILL STALL. The engine will
stall after the shut-off delay. Idling stop is an option. If the
option has not been selected, there will be no alarm and
the engine will not be shut off.
- If temperature of the engine coolant has been over the

set limit value for a specified amount of time, the display
will show alarm: ENGINE WATER TOO HOT and the en-
gine will be shut off. (If temperature has been over set
alarm limit, maximum power will be limited and display
will show alarm: ENGINE WATER TOO HOT)
- If oil pressure has been under the set value for a speci-
fied amount of time, the display will show alarm: ENGINE
OIL PRESSURE LOW and the engine will be shut off. (If
oil pressure is below alarm limit, maximum power will be
limited and the display will show alarm: ENGINE OIL
PRESSURE LOW)
- Engine's temperature/pressure stopping is an option. If

the option has not been selected, the engine will not stall
but maximum power will be limited.
When one of the above conditions is met, A82_PRO1 is

deactivated for 3 seconds, then the engine will be shut off
but you can get engine data after that. At the same time
the operating hour counter is deactivated
04.3.9.3 Normal Operation of the Engine

Normal operation of the engine mainly consists of analy-
sis of position of the gas pedal, transmission of engine
control messages to A86 and reception of status messag-
es from A86. Information regarding errors is also brought

Electric Systems 33
to the display. Engine rpm value can also be limited ac-

cording to the status of the engine.
Maximum rpm value is limited according to the following

conditions. If the cause for limitation disappears, gas lim-
itation will only disappear after the gas value falls below
10%.
- RSV: If the gas pedal has been pressed and direction

has been selected forward and rpm is above runaway lim-
it Ægas request at 0%.
Changing of direction situation and speed below direction

change limit km/h Ægas request at 0% and rpm below
runaway limit.
- Changing gears Ægas request at 0% until slide ratio is

reached.
- After declutch Æ gas request at 0%, max speed 15km/h.
- Engine coolant has overheated (shut-off limit _C) Æ

alarm to display and shut-off of engine. If the coolant has
overheated above alarm limit, maximum power is limited
and display will show alarm: ENGINE WATER TOO HOT.
Time coercion will prevent wandering of the engine rpm.
- If engine oil pressure is below alarm limit, maximum

power will be limited and the display will show alarm: EN-
GINE OIL PRESSURE LOW.
- If A86 has detected an error in the engine's temperature

or oil pressure or engine's rpm sensor, maximum power
is limited and the display will show alarm: ERROR EN-
GINE TEMPERATURE, ERROR ENGINE OIL PRES-
SURE or ERROR ENGINE RPM. The driver's display
shows as values 0 _C, 0 bar or 0 rpm, but the program
uses normal values, so the engine operates otherwise
normally. If the display shows any of the above alarms,
you must take in the machine for maintenance immedi-
ately.
When the rpm value is higher than 900 or the lever is in

motion, effective operating hour counter is activated. Cor-
respondingly, the effective operating hour counter is de-
activated, when rpm is lower than 900 or the lever is not
in motion.
If engine's under-temperature option has been selected,

engine water's temperature is monitored while the ma-
chine is running. If temperature has been below the set
value for a specified amount of time, the display will show

34 Electric Systems
alarm: ENGINE UNDERTEMPERATURE. The alarm

does not affect operation of the machine.
If engine's water level is low (A81_DI1=1) the display will

show alarm: ENGINE WATER LEVEL TOO LOW. The
alarm does not affect operation of the machine.
If data transfer to the engine (to A86) breaks down, the

display will show alarm: ERROR CAN MOOTTORI. The
program monitors that the engine sends an rpm value at
regular intervals. If the bus is broken, the engine control
unit (A86) will guide the engine into idling.

Electric Systems 35
04.3.10 Control of Boom and Spreader
04.3.10.1 Valve Control in Various Functions
Y67,
Y58 Y57 Y51 Y52 Y56 Y87 Y59a Y59b Y71b
Function Y68
PRO2 PRO4 PRO1 PRO3 DO1 DO3 PRO6 PRO5 DO3
DO2
L X
LE X X
LR X X
E X
R X
LO X X
LOE X X X
LOR X X X
A81 X
QL X X X
RCC X X
RC X X
Function code:
L Lifting
E Extension
R Retraction
LO Lowering
QL Quick lift
RC Rotation clockwise
RCC Rotation counter clockwise
A81 Free rotation
E.g. function LE = Lifting + Extension
04.3.10.2 Boom Movements

Boom movements are controlled by the joystick. Lifting,
lowering, telescope out and in movements have pwm per-

36 Electric Systems
centage control Rotations specify power mA. Lowering

and lifting movements are also affected by the pressure
of the lifting cylinder. Boom out and in movements are
also affected by a damping function.
twist locks open=1 or

twist locks closed=1 or
(S194=1 and
S189 = 1)
yes
kyll
Rear stability disconnect yes

kyll
Stability disconnect yes
kyll
S85 = 1
S85 = 1
ei
no
no
ei
kyll
yes
yes
kyll
Container
Conteiner contact
Rear stability disconnect kyll
yes
contact
yes yes
ei
kyll
S85 = 1
ei
no
Parameter no
ei rotating rotating
time past counter- clockwise
yes clockwise
limit=0 limit=0
no
yes yes
hoisting=1 rotating tel in=1

lowering=1 tel out=1 rotating
and clockwise=1 counter- clockwise and
and and tel =1
owering=0 in=0 and and tel out=0
hoisting=0 rotating rotating
counter- clockwise clockwise
=0 =0
yes yes yes yes

yes yes
LIFTING ROTATING ROTATING RETRACTION

LOWERING EXTENSION
CLOCKWISE COUNTERCLOCKWISE
Figure 11. Conditions of Boom Movements when using

Stability Guard1

Electric Systems 37
twist locks open=1 or

twist locks closed=1 or
(S194=1 and
S189 = 1)
yes
Rear stability disconnect Yes

Rear stability disconnect yes
kyllä yes
Stability disconnect kyllä
S85 = 1
S85 = 1 S85 = 1
no
ei No
no
ei
yes
Yes
yes
kyllä
Reached
angle <50
degree
Container
Container contact
yes
kyllä contact
ei
no
kyllä
yes
Gabarity
> -1,0 m
Gabarity
> - 1.0m
Parameter
time passed yes
ei rotating rotating
clockwise counter- clockwise
limit=0 limit=0 yes
yes
kyllä
no
yes yes
lifting =1 rotating tel in=1

lowering=1 tel out=1 rotating
and clockwise=1 counter- clockwise and
and and tel =1
lowering=0 in=0 and and tel out=0
hoisting=0 rotating rotating
counter- clockwise clockwise
=0 =0
yes yes yes yes

yes yes
LIFTING ROTATING ROTATING RETRACTION

LOWERING EXTENSION
CLOCKWISE COUNTERCLOCKWISE
Figure 12. Conditions of Boom Movements when using

Stability Guard2
The boom movements are defined with four handle (%)

and control /(mA) value, parameters I9-L28. To the lift
and drop movement it affects also the pressure of lifting
cylinder. To the telescope out and in movements it affects
also the decelerations.
04.3.10.3 Spreader Movements

Extension and Shortening
In order for you to extend or shorten, container contact is
not allowed and the twistlocks must be open. You can se-
lect with switches to extend/shorten with one button bot
left and right side, or extend/shorten left side with one but-
ton and right side with another button.
If automatic function or 30' stop buttons have not been se-

lected, valve control occurs without limit switches. Auto-

38 Electric Systems
matic function has limit switches on right and left side,

and 30' stop has also limit switches on right and left side.
A83_DI1=0
AND A83_DI2=0
AND
A84_DI14B=0
A83_DI7
=0 OR
A84_DI10A
=1
A84_DI4A A84_DI15A A84_DI12A A84_DI14A A84_DI13A A84_DI5A

=1 =1 =1 =1 =1 =1
/S86/ /S191 /S193/ /S191/ /S193/ /S95/
A84_DI9A
A84_DI11A TRUE =1
=1 /S237/
/S189/
FALSE
TRUE
FALSE
A83_DI3=0 A83_DI4=0
/S136/ /S236/ AND
A83_DI3=0
A83_DI5=0 A83_DI6=0
/S135/ /S235/ AND
A83_DI5=0
A83_PRO1 A83_PRO2 A83_DO1=1 A81_DO1=1

A83_DO2=1
=100% =100%
SPREADER SPREADER SPREADER SPREADER FREE CIRCULATION

LENGTHENING LEFT LENGTHENING RIGHT SHORTENING LEFT SHORTENING RIGHT VALVE
Figure 13. Extension and Shortening of Spreader

Electric Systems 39
Rotations
Rotation is allowed, if stability is not on cut-off, if there is
no container contact, if the twistlocks are open, closed or
if their by-pass is pressed. There are limit switches for
both directions (clockwise, counterclockwise). You can
also take into use the "additional limits" option with a pa-
rameter. If the option has been selected and if the boom's
position data is correct, additional limits will be used.
There is a by-pass switch for the additional limits.

40 Electric Systems
A81_AI5 > 0 A81_AI6 > 0
TRUE TRUE
STABILITY < STABILITY <

100% OR 100% OR
A81_DI12=1 A81_DI12=1
TRUE TRUE
A83_DI1=0 AND A83_DI1=0 AND

A83_DI2=0 AND A83_DI2=0 AND
A84 DI14B=0 A84 DI14B=0
TRUE TRUE
A83_DI7=1 OR A83_DI7=1 OR
A83_DI8=1 OR A83_DI8=1 OR
A84 DI10A A84_DI10A
TRUE TRUE
A83_DI10=0 A83 DI9=0
TRUE TRUE
OPTIONAL TRUE OPTIONAL

parameter extra A83_AI1>4V AND TRUE
parameter extra A83_AI2>4V AND
limits =1 AND A84 DI15B=0
limits =1 AND A84 DI15B=0
A81 DI8=0
A81 DI8=0
FALSE FALSE
FALSE FALSE
A83_PRO6=X% A81_DO1=1 A83_PRO5=X%
ROTATION CLOCKWISE FREE CIRCULATION ROTATION COUNTER-

VALVE CLOCKWISE
Figure 14. Rotation of Spreader

Electric Systems 41
Tilting
Tilting is allowed, if there is no container contact. In addi-
tion to the direction (left, right, forward, backward) button,
you must use the S99 button. Cross-tilting is an option,
which you can select into use with parameter F28. Lock-
ing switches control the locking valves.

42 Electric Systems
A83_DI1=0 AND
A83_DI2=0 AND
A84_DI14B=0
TRUE OPTIONAL TRUE

parameter
pileslope=1
A84_DI2A=1 A84_DI1A=1 A84_DI4A=1 A84_DI5A=1

/S90/ /S89/ /S86/ /S95/
TRUE TRUE TRUE TRUE
A84_DI3A A84_DI3A A84_DI3A A84_DI3A

=1 =1 =1 =1
/S99/ /S99/ /S99/
/S99/
TRUE TRUE TRUE TRUE
A83_PRO8 A83_DO11 A83_DO5 A83_DO4

=100% =1 A81_DO1=1 =1 =1
PILE SLOPE TO LEFT PILE SLOPE TO RIGHT FREE CIRCULATION SPREADER LONGIT. SPREADER LONGIT.
VALVE TILTING FORWARD TILTING BACKWARD
A84_DI18A=1
/S60/
TRUE
A84_DI7A=1
/S92/
A83_DI7=0
TRUE
TRUE
A83_PRO7
A83_DO12=1 =100%
SPREADER LONGIT.
PILE SLOPE LOCKING TILTING LOCKING
Figure 15. Tilting of the Spreader

Electric Systems 43
Sideshift
Sideshift is allowed, if there is no container contact and if
stability is not on cut-off Right and left sideshift are select-
ed with their own buttons.

44 Electric Systems
A83_DI1=0 AND
A83_DI2=0 AND
A84_DI14B=0
TRUE
STABILITY < 100%

OR A81_DI12=1
TRUE
A84_DI2A=1
A84_DI1A=1
/S90/
/S89/
TRUE
TRUE
A84_DI3A A84_DI3A
=0 =0
/S99/ /S99/
FALSE FALSE
A81_DO1=1 A83_DO7=1
A83_DO6=1
FREE CIRCULATION
SIDE SIFT TO LEFT SIDE SIFT TO RIGHT
VALVE
Figure 16. Sideshift of the Spreader

Electric Systems 45
Twistlocks Manually
The twistlocks open and closed movement require con-
tainer contact. Both movements have a limit switch, which
is used to control the indicator lights.
A84_DI6A=1 A84_DI8A=1
/S180/ /S192/
TRUE
TRUE
A83_DI7=0
A83_DI8=0
/S121,S122/ /S123,S124/
TRUE
TRUE
A84_DI14B=1 (A83_DI1=1
A84_DI14B=1
OR (A83_DI1=1 AND A83_DI2=1)
OR (A83_DI1=1
A83_DI8=1 AND A83_DI7=1
OR
AND A84_DI14B=1
/S121,S122/ A83_DI2=1) /S123,S124/
A83_DI2=1)
TRUE TRUE
TRUE TRUE TRUE
A83_DO10=1 A83_PRO3 A83_DO9=1

A81_DO1=1 A83_DO3=1 A83_DO8=1
=100%
FREE CIRCULATION TWIST LOCKS CONTAINER

TWIST LOCKS
VALVE CLOSE CONTACT
OPEN
Figure 17. Twistlocks Open and Closed Manually

46 Electric Systems
04.3.11 Monitoring of Stability

Status of stability is displayed continuously on the driver's
basic display graphically and in percentages %
When stability has been over 90% for more than 1 sec-
ond, boom movement out or spreader rotation is active,
the buzzer alarms periodically (except stability guard2: If
reach is < 3,5 m, there will be no alarm but movements
are forbidden). When stability exceeds 100%, lifting, low-
ering, boom movement out and spreader rotation are pre-
vented, the buzzer alarms constantly. Stability by-pass
switch S85 permits movements. If there is a sensor error
(B6, B8, R60, R61), the buzzer rings twice and the display
will show an alarm. Then boom movements are prevent-
ed (stability by-pass switch S85 permits movements).
Monitoring of stability can be carried out in two ways:
• Stability guard 1 = rear axle sensor and amplifier,

standard. Rear axle's overload protector is available
as an option.
• Stability guard 2 = length and angle sensor and two lift-

ing cylinder pressure transmitters, option.
04.3.12 Load Weighing
04.3.12.1 Stability Guard 1

Operation of the weighing system is based on change in
pressure of the lifting cylinder, which is measured by
pressure transmitter B6. Pressure transmitter's data is
converted into weight of the container on the display.
Weighing is done in boom position determined by sen-
sors S79. Conditions of weighing display are: boom in
A83:DI11 = 1 and angle data S79 A81:DI9 = 1 and ma-
chine does not move A82:DI2<100Hz and boom move-
ments are not made. When the above conditions are met,
item "load weighing" on basic display will always show
stars, which means that weighing is done, if the machine
does not move and boom movements are not made. First
weighing result comes in 3 seconds, when pressure level
has stabilized. After that the weighing result is shown on
the display as long as you are in that status, the display is
updated at 1 sec. Intervals. When you leave the weighing
status, the display does not show any weighing result. A
weighing result shown on the display is always in the
range of 0-46 tons. Weighing should always be done after
a lifting movement.
Weighing is an option, when you are using stability guard

1.

Electric Systems 47
04.3.12.2 Stability Guard 2

Load's value is calculated from lifting cylinder's pressure
transmitters B6 A82:AI5 and B8 A82:AI4 as an average
value. Measurement result is the average value of two
sensors. The measurement result is shown on the display
for load weighing only, when the machine's speed is 0-2
km/h and there is no lifting or lowering movement (3 sec-
ond delay after lifting and lowering). A weighing result
shown on the display is always in the range of 0-46 tons.
If the machine is in motion, the weighing value on the dis-
play is not updated (result does not change).
Weighing is standard, when you are using stability guard

2.

48 Electric Systems
04.3.13 Calibrations
Calibration settings must be checked and calibrated at
1000 h intervals and every time you have handled sen-
sors (A312, B6, B8, R60, R61), which affect the calibra-
tions.
Calibration settings are made on the display. Move to cal-

ibration displays by turning S3 key switch to ON position
(located in the cabin's electric box) and then pressing M
button 3 times during 2 seconds. The display will show
message: CALIBRATION ARE YOU SURE? Move to cal-
ibration settings by pressing the OK key. (Use the -> key
to stop calibration and return to basic display.)
CALIBRATION
ARE YOU SURE
Figure 18. Calibration Display
Calibration displays vary according to options installed in

the machine as follows:
• Calibrate Stability 1 (if there are no options, Stability 2)
• Calibrate gas
• Calibrate pressure weighing, option (if there are

Stability 1)
• Calibrate Stability 2, option
Calibrations should be performed, while the machine is

on an even surface. For load you need a container,
whose weight you know precisely (over 20 t).
During calibration the stability guard is not in operation,

but the buzzer will alarm at 90%. Boom retardation is not
in use during calibration.

Electric Systems 49
Warning!
You must make calibrations carefully according to
the instructions, otherwise operation of the machine
and safety are compromised!
04.3.13.1 Calibrate Stability 1

Display shows text: CALIBRATE STABILITY 1.
1. Press OK
Display shows text: BOOM DOWN AND IN n.n.
2. Drive boom fully in and down without a load.

3. Wait for 10 seconds and press OK
Program reads a value, which corresponds to stability
0%. Next display appears automatically.
Display shows text: REAR WHEELS UP n.n
4. Grab the load and drive the boom slowly out with the
load low (about 10 cm from the ground), so that the
rear wheels just about rise into the air.
5. Wait for 10 seconds and press OK
Program accepts a value, which is at least 2V smaller
than the previous value, which had no load. Program
caclulates the stability linearly with the help of the
points and determines an alarm limit (90%) and max.
allowed limit (100%).
When the acceptable calibration values have been

stored, the next display appears automatically.
Display shows text: CALIBRATION OK for 2 seconds,

and after that it returns to the basic display.
6. Finish calibration by resetting the system by switching

off and on again power of the machine.
Warning!
Note. Do not switch off power of the machine until
display shows the basic display. Otherwise the cali-
bration values are not saved correctly.
04.3.13.2 Calibrate Stability 2

The boom decelerations are not valid when the ”calibrate
stability2” is accepted with OK in the calibration menu, so
the situation is the same as the by-pass switch pressed to
bottom.

50 Electric Systems
When calibrated the boom is asked to drive completely in,

then the minimum value of the length sensor will be re-
ceived. When driven the boom out, it will be have the
maximum value of the length sensor.
BOOM IN
• The boom is telescoped completely in.
• 0,1 < length sensor voltage < 0,3
• Boom in is accepted with the OK button
• 0,2V is a recommended value; also 0,1 and 0,3 are

acceptable.
BOOM OUT
• The boom is telescoped completely out.
• 4,7 < length sensor voltage < 4,9
• Boom out is accepted with the OK button.
• 4,8V is a recommended value, also 4,7 and 4,9 are

acceptable
When the boom is down it will have the minimum value for
the angle sensor and when up the maximum value.
BOOM DOWN
• The boom is dropped completely down.
• 0,4 < angle sensor voltage < 0,8
• Boom down is accepted with the OK button.
About 0,5V is a recommended value 0,4 is minimum

and 0,8 maximum which are also accepted.
BOOM UP
• The boom is lifted completely up.
• 2,9 < angle sensor voltage < 3,5
• Boom up is accepted with the OK button.
About 3,5V is an accepted value. 2,9 is minimum and 3,5

maximum values which are also accepted. When the cal-
ibration is made and the calibration values are saved,
“OK” will appear on the display.

Electric Systems 51
04.3.13.3 Calibrate Gas

You should calibrate the sensor of the gas pedal every
time you replace the pedal. The program contains default
values, which allow the gas pedal to function before pa-
rameters are loaded. However, you must calibrate the
gas as soon as possible.
Calibrate the gas pedal as follows: power is on but engine

is not running.
1. Move to calibration displays. Press the OK key, and if

the display then shows text: CALIBRATE STABILITY
1, move to calibration by pressing the "arrow down"
key.
Display shows text: CALIBRATE GAS.
2. Press OK
Display shows text: PRESS GAS ALL THE WAY
DOWN.
3. Press gas all the way down and at the same time press
the OK key, and the program will read the voltage val-
ue. Next display appears automatically.
Display shows text: RELEASE GAS.
4. Release the gas pedal and press the OK key, and the
program will read the voltage value. The program ac-
cepts the calibration when the previous, with the pedal
all the way down, is at least 1V higher.
When the acceptable calibration values have been
stored, the next display will appear automatically.

and after that it returns to the basic display.

Warning!
display shows the basic display.Otherwise the cali-

52 Electric Systems
04.3.13.4 Calibrate Pressure Weighing (option)

Pressure weighing shows weight of the load based on
voltage values of one pressure transmitter in one position
of the boom as determined by sensors S79. Conditions of
the weighing display are: boom in A83:DI11 = 1 and angle
data S79 A81:DI9 = 1 and machine does not move
A82:DI2<100Hz and boom movements are not made.
Note. We recommend that you make the calibration after

a lifting movement.
1. Move to calibration displays. After you have pressed

OK button, if the display shows text: CALIBRATE STA-
BILITY 1, you can access weighing calibration by
pressing "arrow down" key 2 times.
Display shows text: CALIBRATE PRESSURE
WEIGHING
2. Press OK
Lift boom without a load to weighing spot, and the dis-
play will show signs **.* t
Display shows text: BOOM WITHOUT LOAD **.* t
3. Press OK
Pressing of OK key is allowed, after you have been at
the calibration item for at least 3 seconds. Program
read the voltage, which corresponds to 0,0 t. Following
display changes automatically.
Display shows text: BOOM WITH LOAD **.* t
4. Lift load container (whose weight you know) to weigh-

ing spot, and the display will show sign **.* t . Enter
from the display weight in tons with accuracy of one
decimal (nn,n).
5. Press OK
Pressing of OK is allowed, after you have been at the
calibration item for at least 3 seconds. Program reads
the voltage, which corresponds to the entered weight
and checks that the previous value without a load is
smaller than with the load. When acceptable calibra-
tion values have been saved, the following display
changes automatically.

and then returns to the basic display.

Electric Systems 53

Warning!
display shows the basic display.Otherwise the cali-
04.3.13.5 Pressure Weighing Fixed Scale

When the calibration point is correct, A83_DI11 = 1 and
A81_DI9 = 1, stars will appear on the calibration display
indicating that the calibration can be made. It is recom-
mended that the fcalibration will be made after the lifting
movement.
The boom is lifted without load to the calibration point and

the OK button is pressed on the display. Pressing of the
OK button is allowed when A83_DI11 and A81_DI9 have
been 1 at least for three seconds. When pressing the OK
button the program reads the corresponding voltage (X),
which corresponds to 0 ton.
The container, the weight of which is known in tons, is lift-

ed to the calibration point. The weight is written with one
decimal from the display and is exited with the OK button.
Pressing of the OK button is allowed when the A83_DI11
and A81_DI9 have been at 1 for at least three seconds.
When pressing the OK button, the program reads the cor-
responding voltage (/) which corresponds to the written
load.

54 Electric Systems
The program checks that the calibration value “boom

without load” is less than the value “boom with load” and
that the calibration values will be saved. The calibration
has been made correctly if an OK message appears on
the display. The program makes scaling linear with two
calibration points. The scaling top level, max is counted
according to the formula described in the following figure.
Figure 19. Calibration Points, Scaling

Electric Systems 55
04.3.14 Functions of By-pass and Emergency

Switches
S189
A84_DI11A. Locking switch, which in its bottom position
stops toplift's automatic extension/shortening movement.
S194
A81 DI10A. By-passes shafts open/closed data of toplift's
sensors. If S194 is pressed down, boom's lowering and
lifting functions are possible, even if shafts open/closed
data is missing. Switch does not by-pass stability.
S85
A81 DI12. Stability guard's by-pass switch by-passes sta-
bility guard, when the shafts are open or closed or when
you have pressed S189+S194. Switch permits lifting and
lowering of the boom and telescoping out, also permits
rotations. Stability does not affect telescoping in of the
boom. Telescoping in of the boom is allowed, when sta-
bility is 100%.
S199
A84_DI14B. Container contact by-pass switch. Permits
open movement of shafts, even if container contact is
missing. You can only use the switch when the container
is on a stable surface (on the ground).
S112
A84_DI1B. Emergency stop switch shuts off the engine,
and you cannot start the engine until you have released
the switch
S186*
A82_AI8 gas control. Controls the gas directly without
conditions 1,6V.
S187*
A82_PRO4 start of engine and A82_PRO1 engine run-
ning/stop. Press the button during starting, engine will re-
main running, you can also shut off the engine from the
switch. Controls directly without conditions.
S188*
A82_PRO3, A82_PRO2 directions and A82_DO2,
A82_DO3 2-gear. You can use the switch to select direc-
tion forward or backward and 2-gear. Controls directly
without conditions.

56 Electric Systems
*) Use of the by-pass button by-passes all protectors of

the control system. Use is only permitted for transfer driv-
ing to the repair shop.
04.3.15 Bus Errors

The display monitors that it receives messages from each
module (A81, A82,A83,A84 and A86 (ECU engine) at
specified intervals. If reception of message stops (>1s),
the display will show an alarm. A81 module also checks
that it receives messages from A82 module. If it does not,
critical movements will be forbidden. A bus alarm occurs
when a bus is broken or a module has fallen out of the en-
tire system. First you should check whether a modules
LED lights are burning, and if they are, then you should
check the bus for errors.
1. Bus connection broken between A80 and A84
• Machine operates normally without the display.
• Display will show alarms ERROR CAN A81, ERROR

CAN A82, ERROR CAN A83, ERROR CAN ENGINE
• Stability on display 0%, boom movements are forbid-

den, by--pass switch S85 permits movements, spread-
er movements do not function (switches on A84
module).
• Display shows engine data (rpm, _C, bar) as zeroes,

engine will not start from the key but will start from by-
-pass switch S187. Directions do not function normal-
ly, but will function with by--pass switch S188. Gas
functions.

CAN A83, ERROR CAN ENGINE

module).
• Display shows engine data (rpm, _C, bar) as zeroes,

engine will not start from the key but will start from the
by--pass switch S187. Directions do not function nor-
mally, but will function with the by--pass switch S188.
Gas functions, A81 controls it.

Electric Systems 57
4. Bus connection broken between A81 and engine A86

(ECU)

CAN ENGINE

module).
• Display shows engine data (rpm,_C, bar) as zeroes,

engine will not start from the key but will start from the
by--pass switch S187. Directions do not function nor-
mally, but will function with the by--pass switch S188.
Gas does not function.
5. Bus connection broken between engine A86 (ECU)

and A83
• Display will show alarms ERROR CAN A83

module).
• Display shows engine data normally, engine will start

from the key. Directions do not function normally, but
will function with the by--pass switch S188. Gas func-
tions.
6. Control unit falls out of the system
• A81, alarm ERROR CAN A81. Boom movements do

not function even with the by--pass switch. Spreader
movements do not function, because free rotation is
on A84 module. Stability is 100%, engine functions
and starts and gears function.
• A82, alarm ERROR CAN A82. You can engage

gears and direction with the by--pass button S188.
You can start and shut off the engine with S187 button.
Gas functions with the by-pass button S186. By-pass
switch S85 permits boom movements.
• A83, alarm ERROR CAN A83. Spreader movements

do not function, boom movements will function with
S194 by--pass.
• A84, alarm ERROR CAN A84 and EMERGENCY--

STOP PRESSED. Boom movements function,

58 Electric Systems
spreader movements do not function. Engine will start

with the by--pass switch S187, gears and directions
function with the by-pass switch S188. Gas functions.
04.3.16 Replacement of a Module

If you replace a control module of the machine, you must
load the machine-specific software to it. Loading is done
at the factory in connection with the spare part delivery.
When you order a new module, you must specify the de-
vice code of said module (A80, A81, A82 or A83) and the
machine's serial number.
You must always perform the calibrations after you have

replaced a module. See item Calibration.

Electric Systems 59
04.4 Electric Equipment for the Power

Unit Scania DI12 EDC/PDE
A
A
1 2 R6- S11
S12- R7 R9
K201 R7- S12
K2
S6
G1
Y3
Y2 B1
M1 Y1 B1
Y4
Y5
S10
R4
1 R6 S11
S12- R7 3
4
R9
2 R7 S12
3 R9 B1
S11- R6
4 R4/S10
Figure 20. Electric Equipment for the Power Unit
1 Engine oil pressure sensor

2 Boost temperature / pressure sensor
3 Coolant temperature sensor
4 Engine RPM sensor
B1 Transmission output sensor
G1 Alternator
K2 Start solenoid
K201 Air conditioner magnet switch (optional)
M1 Start motor
R9 Hydr.oil temperature
R4/ S10 Engine coolant temperature sensor / switch
S6 Electronic control module ECM
R6/ S11 Transmission temperature sensor / switch
R7/ S12 Transmission pressure sensor / switch
Y1 -Y5 Solenoids of gear shift

60 Electric Systems
04.5 Electric Equipment for the Power

Unit
S10- R4
S12- R7
G1
S11- R6 B1 S11
B1
B2
B2 S12
R6
A86 K2 S12 R7
ECM R5
S9
Y4
M1 Y5
Y2
Y1
Y3
Figure 21. Electric Equipment for the Power Unit
A86 Electronic control module ECM

B1 Transmission output sensor
B2 Engine RPM sensor
G1 Alternator
M1 Starting motor
K2 Starting solenoid
R6 Transmission temperature
S11 Transmission temperature switch
S12 Transmission pressure switch
Y1 -Y5 Solenoids of gear shift

Electric Systems 61
04.6 Electrical Equipment in the Frame
E39 V1- V7
F1 3 1
7 5 9 1 1315
1 3 5 7 9 111315
X3 X5 F34 F42
F2 2 4 6 8 10 14
16
12
F35 F43
4 2
8 6 10 X1 X6 F36 F44
F45
F3 A81 F37
F38 F46
X2 X7 F39 F47
F48
F4 F40
X4 F41 F49
DI12 QSM11
(X39)
XR3
X85
X37
X35
X95
3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1
6 5 4 6 5 4 6 5 4 6 5 4 6 5 4 6 5 4 6 5 4
9 8 7 9 8 7 9 8 7 9 8 7 9 8 7 9 8 7 9 8 7
XEC
X78
X21
X31
X38
3 2 1
6 5 4
3 2 1
6 5 4
3 2 1
6 5 4
3 2 1
6 5 4
3 2 1
6 5 4
3 2 1
6 5 4
3 2 1
6 5 4
S297
9 8 7 9 8 7 9 8 7 9 8 7 9 8 7 9 8 7 9 8 7
S296
Figure 22. Electrical Equipment in Frame

62 Electric Systems
A81 Control module

A85 Amplifier (stability)
E39 Service light
K71 Relay, brakes cooler
K72 Relay, hydraulics cooler
S296 Switch, cabin transfering
S297 Switch, cabin transfering
V Diodes
QSM11 Cummins datalink
DI12 Scania datalink
Fuses
F1 Main fuse, cabin (50A)
F2 Main fuse, cabin (50A)
F3 Main fuse, frame/hydraulics (50A)
F4 Main fuse before main switch (50A)
F34 Hydraulics cooler (15A)
F35 Brakes Cooler (15A)
F36 Control module A83 (10A)
F37 Hydraulics (10A)
F38 Control module A81 (10A)
F39 Engine (10A)
F40 Cabin before main switch (25A)
F41 Cabin transfer, engine (10A)
F42- F49 Options
F43 Scania power (90A)
Connectors
X37 Cabin - boom
X35 Cabin - frame
(X39) Main switch, Cabin boom in
X85 Cabin - frame
X95 Cabin - frame
XR3 Main switch - cabin
X38 CAN-connector, boom - engine
X21 Cabin - engine
X31 Cabin - engine
X78 Cabin - engine
XEC Cabin - engine

Cabin 1
05 Cabin
05.1 Electric Equipment for Cabin ........................................................... 2
05.1.1 Electric Box for Cabin ............................................................. 2
05.1.2 Connectors for Cabin .............................................................. 5
05.2 Electric Control System of Engine Speed - Scania ........................ 6

05.2.1 General ................................................................................... 6
05.3 Electric Control System of Engine Speed - Cummins ................... 7

05.3.1 General ................................................................................... 7
05.4 Intake Air Filter and Windscreen Washer Filling ............................ 8

2 Cabin
05.1 Electric Equipment for Cabin

05.1.1 Electric Box for Cabin
S186 S187 S188
*
A13
*
A12 Option
Seat heater
R6 R8
1 3 5 17
1 9
1 3 5 17
1 9
K19 K13 K17

2 4 6 12
8 10
2 4 6 12
8 10
F10 F11 F12 F13 F14 F15 F16 F17

H13 S3
F18 F19 F20 F21 F22 F23 F24 F25
F26 F27 F28 F29 F30 F31 F32 F33

X44 XPO XR1 XSR
9 40 18 1
8 41 17 2
1
7 42 16 3
2
6 43 15 4
3
5 44 14 5
4
XS1 X191 XR2 XR3 XHR

4 45 13 6
5
3 46 12 7
6
2 47 11 8
A84 A82
1 48 10 9
9 49 9 1
8 50 8 2
7 51 7 3
1
6
5
52
53
6
5
4
5
X115 X82 X32 X36
4 54 4 6
2
3 55 3 7
3
2 56 2 8
4
57 1 9
5 1
6
7 X21 X31 X35 X95 XGE5
Figure 1. Electric Box for Cabin

Cabin 3
A12 Voltage reducer (optional)

A13 Voltage reducer (optional)
A82 Control module
A84 Control module
H13 Alarm buzzer
R6 Resistor 200ohm
R8 Resistor 200ohm
S3 Maintenance switch
S186 Gas pedal by-pass
S187 Engine start
S188 Gear holding
Relays
K13 Sound signal
K17 Flashing relay
K19 Reversing light and alarm
Fuses
F10 Fan Heater (15A)
F11 Condenser fan (15A)
F12 Seat heater / compressor seat (15A) (optional)
F13 Alarm lights gauges (10A)
F14 Reserved (10A)
F15 Reserved (10A)
F16 Control modules A80, A82 and A84 feed (10A)
F17 Parking brake (10A)
F18 Driving and parking lights (10A)
F19 Flashing beacon (10A)
F20 Reversing lights alarm (10A)
F21 Turn signal lights (10A)
F22 Working lights, boom (10A)
F23 Working lights, boom (10A)
F24 Working lights, front on the roof (10A)
F25 Working lights, rear on the roof (10A)
F26 Working lights, spreader (10A)
F27 Front window wiper and washer (10A)
F28 Rear window wiper and washer (10A)
F29 Roof window wiper and washer (10A)
F30 By-pass switches (10A)
F31 Reserved (10A)
F32 Cabin transferring (10A)
F33 Engine stopping delay, (10A)
(optional)

4 Cabin
Connectors
XR1 Spare wirings from hand lever panel
XSR Spare wirings from front panels
XR2
XHR
XR3 Spare wirings from supply cable chassi
XP0 Forced drive control panel
X44 From air conditioner
X191 From mini steering wheel
XS1 From hand lever panel
XGE5
X22, From front panels
X37
X21, From frame
X31,
X35,
X95,
X82,
X115
X32 From roof
X36
XPC From display

Cabin 5
05.1.2 Connectors for Cabin
*
E35
+12V 6A MAX
X32B
E30 X36B
+24V 6A MAX *
* F37 S97A E34
E32 S97B
M7 *
E33
A312 X190 M5
XGE
S980
XR1
XR2 *
+24V / 12V 6A MAX
X308 XSR
X309 S7
X310
X1
X2 S990
X3 A80 +24V 6A MAX
F37
H13
S52
S23 K33
K34 *
M911 M3 K35 *
M212
M222 X350 X355 X304
X32 XP0 X115
RM212 X351 X356 X305
M4 X36 XSR X82
RM222 X352 X319 X306
M6 XS1 XR2 X21
XS2 X307
M8 GE5 XHR X31
XSR *OPTION
XR1 XR3 X35
X191 X95
X44
Figure 2. Connectors for Cabin

6 Cabin
05.2 Electric Control System of Engine

Speed - Scania
05.2.1 General
The movement of the acceleration pedal in the electric
control system of engine speed is transferred as an elec-
tric signal message to the engine.
A312
A82
A96 2
Figure 3. Devices of the Electric Control System of

Engine Speed
1 Acceleration pedal
2 Engine Scania DSI12
A82 Control unit
A312 Potentiometer
A96 Engine control unit
Message of the function position of the acceleration pedal

(1) is transmitted through the potentiometer (A311) and
control unit (A82) to an engine control unit (A96), which
controls the function of the engine injectors .

Cabin 7
05.3 Electric Control System of Engine

Speed - Cummins
05.3.1 General
The movement of the acceleration pedal in the electric
control system of engine speed is transferred as an elec-
tric signal message to the engine.
A312
2
A86
Figure 4. Devices of the Electric Control System of

Engine Speed
1 Acceleration pedal
2 Engine Cummins QSM11
A86 Engine control unit
A312 Potentiometer
Message of the function position of the acceleration pedal

(1) is transmitted through the potentiometer (A312) to the
engine control unit (A86), which controls the function of
the engine injectors.

8 Cabin
05.4 Intake Air Filter and Windscreen

Washer Filling
Take care, that the visibility in the working area is not lim-
ited.
Check the function of windscreen wipers (1) and the level

of the washing fluid in the reservoir. Fill up, if necessary
(3). Pay attention to the machine operating temperature,
by defining the mixture ratio of washing fluid.
2 3
Figure 5. Air Filter and Windscreen Washer Filling
1 Windscreen wipers
2 Intake air filter
3 Filling cap for windscreen washer liquid

Working Devices 1
06 Working Devices
06.1 Maintenance of the Boom ................................................................ 2
06.1.1 Maintenance Points of the Boom ............................................ 2
06.1.2 Slide Guides and Telescope Cylinder ..................................... 3
06.1.3 Adjustment of Play in the Boom .............................................. 4
06.1.4 Checking the Slide Parts ........................................................ 4
06.1.5 Replacing Slide Parts in Front End of the Boom .................... 5
06.1.6 Replacing Slide Parts in Rear End of the Boom: .................... 6
06.1.7 Mounting the Telescope Cylinder ........................................... 7
06.1.8 Electrical Equipment of Boom ................................................. 8
06.1.9 Lift Cylinder ............................................................................. 9
06.2 Maintenance for Lifting Device ...................................................... 10

06.2.1 Turning Device and Side Sift Carriage ................................. 10
06.2.2 Container Handling Device (Toplift) ...................................... 11
06.2.3 Rotation Transmission Maintenance Points ......................... 13
06.2.4 Electrical Equipment for Spreader ........................................ 14
06.3 Inspection Intervals for the Twistlocks of the Spreader ............. 16

06.3.1 Disassembly and Assembly .................................................. 16
06.3.2 Inspection of the Twistlocks .................................................. 17
06.3.3 Information for Guidance ...................................................... 17

2 Working Devices
06.1 Maintenance of the Boom

06.1.1 Maintenance Points of the Boom
7 7
2 5
A
3
2 2
KP06- 0117
Figure 1. Maintenance Points of the Boom
Item Obs.
2 Slide pieces for boom front Daily lubrication, if there is not
end central lubrication
3 Boom bearings Daily lubrication, if there is not
central lubrication
5 Upper sliding surfaces of Spread coating
inner boom
6 Boom support rollers Lubrication
7 Shims for bearings Centralize the boom with
shims

Working Devices 3
06.1.2 Slide Guides and Telescope Cylinder
1
7
8
2
9
3 10
11
A-- A
D 4 C
4
13 Min. 19- 21
12
A
5
A X
10 8
7
11
10 11 9 6 X
9
B- B
Figure 2. Slide Guides and Mounting the Cylinder

4 Working Devices
1 Slide part
2 Slide part
3 Slide part
4 Slide part
5 Slide part
6 Slide part
7 Screw
8 Mounting plate
9 Shim
10 Slide plate
11 Screw
12 Guide
13 Adjustment screw
06.1.3 Adjustment of Play in the Boom

You should always adjust the play in the boom's outer
and inner pipe when replacing slide parts, and at other
times in accordance with the scheduled maintenance pro-
gram.
Adjust the play between the slide parts ( 1, 2, 3, 5 and 6)

and the boom with shims (9), and the play of slide parts
(4) with regard to the boom with adjustment screws (13).
Total play in the lateral direction can be in range 2 - 4 mm.
When adjusting the play, you should try to use the same
number of shims on opposite sides of the boom, so that
the gap between the outer and inner boom is sufficient on
both sides.
06.1.4 Checking the Slide Parts

Measure the thickness of slide plate (10) in the slide part.
Replace side and upper slide plates (10) if measured
thickness is 14 — 16 mm, and lower slide parts (4) if
measured thickness is 19 — 21 mm. When chamfer C in
the lower slide part (4) has worn off, replace the slide part.
Warning!
When slide parts wear to minimum thickness, lubri-
cation grooves D are so low that lubrication is not
sufficient. This may damage inner pipe of the boom
and the telescope cylinder.

Working Devices 5
06.1.5 Replacing Slide Parts in Front End of the

Boom
In container handling machines, lower spreader on top of
container; in forest machines, lower grapple to the
ground. Move the boom carefully, so that the play be-
tween inner and outer pipe is loosened on that side of the
slide part you want to replace. Remove central lubrication
pipes from all slide parts you want to replace (option).
Replacing Lower (4) and Upper Slide Parts (1):
1. Remove upper slide parts by opening the mounting

screws (7) of the mounting plate (8) and by pulling out
the mounting plate and its slide parts. You must re-
move the upper slide parts, so that the lower slide
parts can come out.
2. Lower the boom, so that the play between inner and

outer pipe moves to the bottom side of the boom.
3. Open the guide's (12) adjustment screws (13) and pull

out the guide and its slide parts.
4. Replace the new slide part and re-install the guide

The guide's bottom surface is designed, so that it
can adapt to movements of the boom. When in-
stalling, make sure that the guide can roll freely.
5. Adjust later play of lower slide parts to 2 — 4 mm with

adjustment screws (13).
6. If necessary, replace new slide plates (10) to upper

slide parts (1) and mount them and their mounting
plates back into place.
7. Measure lateral play with a feeler gauge and adjust it

to 2 — 4 mm by adding or removing shims (9) between
mounting plate (8) and slide plate (10).
Replacing Side Slide Pats (2 and 3):
1. Check that there is play between the slide part you

want to replace and the boom, so that the slide part
can come out.
2. Open mounting screws (7) of the mounting plate (8)

and pull the slide part out.
3. Replace the new slide plate (10) and mount it and its
mounting plate back into place.

6 Working Devices
4. After you have replaced slide parts on one side, re-

place them on the other side.

06.1.6 Replacing Slide Parts in Rear End of the

Boom:
Replacing Side Slide Parts (5):
1. Push out the inner boom by 0,5...1 m.

can come out. If necessary, move the boom carefully.
3. Open mounting screws (7) of the mounting plate (8)

and pull the slide part out.
4. Replace the new slide plate (10) and mount it and its
mounting plate back into place.
5. After you have replaced slide parts on one side, re-

place them on the other side.

Replacing Bottom Slide Parts (6):
1. Pull the inner boom fully in. Check that the mounting
screws (11) of the slide parts are at the holes on the
bottom surface of the boom, so that you can open the
screws.

can come out. If necessary, move the boom carefully.

Working Devices 7
3. Open mounting screws (11) of the slide part (6) and

pull the slide part and its shim out.
4. Mount the new slide part back into place.

boom and slide plate (10).
When all Slide Parts have been Replaced:
Push the boom fully out carefully, and at the same time
check that the play is not smaller than the adjusted 2 — 4
mm at any point. If necessary, re-adjust the play. Re-
install central lubrication pipes (option) and test to
make sure all lubrication items receive enough
grease.
06.1.7 Mounting the Telescope Cylinder
Warning!
Make sure that the cylinder can move in the flange
holes. Item X.

8 Working Devices
06.1.8 Electrical Equipment of Boom
X200
Pg21 7 27
6 28
5 29 39 1
4 30 X2 X1 38 2
3 31 X4 37 3
A83
2 32 36
X3 35 54
1 33
24 6
H21
Pg21 59
7
58
8
X60 BOOM/ CAN

26 1
25 2
6 60
5 61 X8 X7 X6 X5 24 3
4 62
3 63
Pg21 2 64
65
23 4
22 5
Pg21
1
21
20
19
6
7
8 E27
Y59b Pg21
E29
Y63 Y65a
120 X57
R60
R61
S79
Y65b Y59a
S81
S80 E26
E28
E27 E26
E29 E28
X200
H304 H305 H303
X30
RED YELLOW GREEN
Figure 3. Electrical Equipment of Boom
E26 Working light

E29
H21 Flashing light
H303 Signal light green, twistlocks closed, 10W
H304 Signal light red, twistlocks open, 10W
H305 Signal light yellow, container in connection, 10W
R60 Boom's angle sensor (optional)
R61 Boom's length sensor (optional)
S79 Sensor, pressure weighing (optional)
S80 Sensor, damping of telescope in
S81 Sensor, damping of telescope out
X57 Connector, boom end
X60 Connector, basic boom end / CAN
X83 Connector, spreader
Y59 Solenoid valve, spreader rotating
Y63 Solenoid valve, spreader tilting locking
Y65 Solenoid valve, spreader longitudinal tilting

Working Devices 9
06.1.9 Lift Cylinder
Pm6 1 2
* *
Figure 4. Lift Cylinder
1 Lock valve
2 Guide bearing
Pm6 Pressure measurement
* Gasket set
06.1.9.1 Cylinder Mounting

Absolute cleanliness is necessary when assembling the
cylinder. Wash the used parts carefully before starting the
assembly, close with plastic plugs the open connection
points and open the gasket packages just when starting
the assembly. Make sure before starting to work, that
greases and oils used in assembly are suitable for hy-
draulic mounting.
Mount the guide rings so that the connection points of the

rings are not on the same central line. Lubricate with
vaseline the gasket set and guide ring surface before
mounting the piston into the cylinder liner.
Pull the piston carefully into the cleaned cylinder liner.
Make sure that the central lines of the piston rod and the
piston line are so accurately parallel as possible. Oil the
piston rod with hydraulic oil when the piston is pulled into
the pipe. Use for lifting crane or forklift truck, then the
gross weight of the cylinder is about 800 kg.

10 Working Devices
06.2 Maintenance for Lifting Device

06.2.1 Turning Device and Side Sift Carriage
1 2
1
3 3
3
4 3
7
1 3
330 - 350 Nm 6 5
3 1
Figure 5. Turning Device and Side Sift Carriage
Maintenance item Note

1 Lubricate bearings of cylinders1)
2 Lubricate shafts of turning device 1)
3 Lubricate slide surfaces for side sift car- Spread coating
riage
4 Lubricate bearings
5 Lubricate bearings of gear rim 1) 4 grease points
6 Gear rim Spread coating
7 Gear oil filling / level dipstick
8 Gear oil drain plug
1)
Central lubrication point (optional equipment)

Working Devices 11
06.2.2 Container Handling Device (Toplift)

The container handling device, toplift is welded steel con-
struction with telescopes on both ends. The length of the
device is hydraulic adjustable for the container sizes ac-
cording ISO and Seeland standards, with length of 20'
and 40'. Optional device for handling of containers of 30'
is available.
3
2 5
A
5 4 1
7 6 6
9
5 3
10
3 1
11
7 7 6
A- A
Figure 6. Container Handling Device (Toplift)

12 Working Devices
Container Handling Device
Maintenance item Note

1 Toplift frame
2 Side sift carriage
3 T-beam
4 Length cylinder Both T-beams
5 Lubricate bearings of the length T-beams have to be in 40'
cylinde position
6 Sliding pads in frame Both ends
7 Sliding pads in T-beam Both T-beams
8 Lubricate slide planes Spread coating, especially
under sides of the beams
9 Lubricate twistlock turning cylin-
der
10 Twistlocks Moveable parts greassed
thoroughly at assembling
11 Lubricate twistlocks
06.2.2.1 Check Sliding Pads

Check the sliding pads during lubrication maintenance.
Adjust the total spacing 1...2 mm with spacing plates.
Change outworn sliding pads.

Working Devices 13
06.2.3 Rotation Transmission Maintenance

Points
2
1
3
4 6
80 Nm
7
Figure 7. Rotation Transmission Maintenance Points
1 Transmission brake oil filling/draining. Fill to sight glass (2)

level (0.6l). Draining: Turn elbow down.
2 Transmission brake oil sight glass
3 Transmission brake breather
4 Transmission oil filling. Fill to sight glass (5) level (2.2l).
5 Transmission oil sight glass
6 Transmission breather
7 Transmission oil drain plug

14 Working Devices
06.2.4 Electrical Equipment for Spreader
The valves of hydraulics
Y73A Y74A Y71B Y62B Y62A Y66--1
Y73B Y74B Y71A Y64B Y64A Y66--2
S125 S127
S99B S98B
S99 S98
S236
S121 S136
S123
S124
E37 E36
S235 X62 S122
S135
S126 S128
X83
Figure 8. Electrical Equipment for Spreader

Working Devices 15
S98 Sensor, rotation clockwise stop

S98B Sensor, 20° limit rotation clockwise (optional)
S99 Sensor, rotation counter-clockwise stop
S99B Sensor, 20° limit rotation counter-clockwise (optional)
S121 Sensor, twistlocks open, left
S122 Sensor, twistlocks open, right
S123 Sensor, twistlocks closed, left
S124 Sensor, twistlocks closed, right
S125 Container contact, front left
S126 Container contact, rear left
S127 Container contact, front right
S128 Container contact, rear right
S135 Sensor, spreader 20’ - 40’ left limit
S136 Sensor, spreader 20’ - 40’ right limit
S235 Sensor, 30’ function left limit
S236 Sensor, 30’ function right limit
X83 Connection
X62 Connection box
E36 Spreader working lights
E37
Y62A Side shift, left
Y62B Side shift, right
Y64A Pile-slope to right (option)
Y64B Pile-slope to left (option)
Y66-1 Pile-slope locking, left (option)
Y66-2 Pile-slope locking, right (option)
Y71A Twistlocks open
Y71B Twistlocks closed
Y73A Lengthening right
Y73B Shortening right
Y74A Lengthening left
Y74B Shortening left

16 Working Devices
06.3 Inspection Intervals for the

Twistlocks of the Spreader
Warning!
The twistlocks must be checked:
First time 5000 operating hours or 2 years whichever
occurs first. Then after the twistlocks must be
checked once a year.
1 300 Nm 2
4
5
3 6
Figure 9. Twistlock Housing
06.3.1 Disassembly and Assembly

1. Disjoin the mounting nut (1) and locking washers (2).
2. Draw the twistlock out (3) from the under side.
3. Check condition of the pivoted level (4) and bearing

housing (5).
4. Check condition and functioning of the contact pin (6)

and spring.
5. Check condition of the twistlock according to the in-

structions.
6. While assembling set the key and locking washers and

tighten the mounting nut 300 Nm.
7. Check that the parts are functioning correct in accord-

ance with the others.

Working Devices 17
06.3.2 Inspection of the Twistlocks

Liquid penetrant examination or magnetic particle exami-
nation shall be used. The area of testing is shown in figure
10. Crack check shall take place every second year or
every 5000 operating hours.
1
Figure 10. 1 = The area of the testing
Note 1: If any cracks are found the twistlocks must be re-

placed immediately!
Note 2: Twistlocks must be replaced if they are visibly

distorted.
Note 3: Twistlocks must be replaced latest at 10.000 h.
Max. 4 mm
m
0
.7
in
M
Figure 11. Wear Limits, Lift Pin
06.3.3 Information for Guidance
06.3.3.1 Liquid Penetrant Examination

Detailed instructions for liquid penetrant examination is
available in, the following publications:
• ASME Boiler and Pressure Vessel Code
• Section V, Nondestructive Examination
• Article 6, Liquid Penetrant Examination

18 Working Devices
• Article 24, Standard methods for liquid penetrant in-

spection, SE-165 (=ASTM E 165)
• SIS 11 45 01
• Draft International Standard ISO/DIS 2694:1973

Working Devices 19
06.3.3.2 Magnetic Particle Examination

References
• Draft International Standard ISO/DIS

2694
• SIS 11 44 01 Magnetpulverprovning
• DIN 54 121 Magnetpulver-PrÜfung
• ASME Boiler and Pressure Vessel Code,
• Section V; Nondestructive Examination:
• Article 7, Magnetic Particle Examination
• Article 25, Magnetic Particle Standards
• SE-109 (=ASTM E 109-63) and
• SE-138 (=ASTM E 138-63) and

20 Working Devices

Equipment 1
08 Equipment
08.1 Air Conditioner .................................................................................. 2
08.1.1 Function of the Air Conditioning Device .................................. 2
08.1.2 Operating Instructions for the Air Conditioner ......................... 3
08.1.3 Maintenance ........................................................................... 4
08.2 Automatic Central Lubrication ....................................................... 12

08.2.1 General ................................................................................. 12
08.2.2 Indicator Lights and Switch in the Instrument Panels ........... 12
08.2.3 Central Lubrication Diagram K5698190 ................................ 14
08.2.4 Central Lubrication Diagram, Toplift ..................................... 16

2 Equipment
08.1 Air Conditioner

08.1.1 Function of the Air Conditioning Device
The circulation of the cold fluid in the air conditioning sys-
tem R-134A installed in the machine, starts from the com-
pressor;1; which press the hot and gaseous cold fluid to
the cooler;2, mounted on the back side of the machine.
The air flow through the cooler transfers the heat from the
cold fluid to the open air, and the cold fluid will condence.
From the cooler the condenced cold fluid is flowing into
the filter; 3;, which separates from the cold fluid humidity
and impurity. From the filter the cold fluid flows into the
expansion valve; 4; which controls the volume of the cold
substance flowing into the evaporator; 5. After the expan-
sion valve the cold fluid pressure in the system is lower-
ing. In the evaporator the cold fluid will vaporize again,
because of lowering pressure. The vaporizing liquid is
binding heat of the air, which flows through the evapora-
tor cell, and the temperature of the cabin will be lower.
The compressor sucks the hot gas from the evaporator
and press it trough the cooler to one new working circu-
lation
L H
Figure 1. Diagram of the Air Conditioner

Equipment 3
1 Compressor
2 Cooler
3 Filter and control glass
4 Expansion valve
5 Evaporator
L Low pressure
H High pressure
08.1.2 Operating Instructions for the Air

Conditioner
08.1.2.1 Warm weather, normal humidity:

Close the recirculation vent and the heating regulator,
turn the cooling system on, and adjust the thermostat as
required.
08.1.2.2 Very warm weather, high humidity:

Open the recirculation vent, close the heating regulator,
turn the cooling system on, and adjust the thermostat as
required.
In autumn and early winter when humidity is high and win-

dows become misty:
Turn the cooling system on, open a window slightly to al-

low air circulation in the cabin. Adjust the heating regula-
tor for desired cabin temperature.
08.1.2.3 Cold winter weather:

Close the recirculation vent, do not turn cooling system
on. adjust the heating regulator for desired temperature.

4 Equipment
08.1.3 Maintenance
The system should be checked once a week, carrying out
the following inspections.
• Sight glass. Bubbles should only appear when the

compressor is started and stopped.
• Check that the connection between the compressor

pressure plate and the pulley is not slipping, and that it
is clean.
• Check that the wire between the thermostat and the

electomagnetic clutch is in good condition.
• Check the drive belt tightness and the compressor

mounting.
• Clean or replace the fresh air and recirculation filters.
• Check the removal of condensate water from the

bottom of the air-conditioner.
• Check all hose connections.
08.1.3.1 Sight Glass Checking Procedure

a) Start the engine and run it at 1500 rpm
b) Turn the air-conditioner on.
c) Set the fan and the thermostat to maximum.
Figure 2. Fluid Container and Sight Glass Mounted to

Top/side

Equipment 5
1 Sight glass
2 Fluid container
3 Pressure switch
Sight glass Description Conclusions and remarks

Continuous Very little refrigerant
stream of bubbles Small temperature difference
or foam-like flow between intake and pressure side.
(add refrigerant). Pressure in output side exception-
ally low.
Stop compressor at once, and
have a specialized mechanic check
the system.
A few bubbles Insufficient amount of refrigerant
every few sec- High-pressure side warm, low-pres-
onds (add refrig- sure side cool.
erant). Check the system for leaks, and
repair possible leaks without delay.
Add refrigerant into the system.
Clear fluid, few Correct amount of refrigerant
bubbles pass Normal pressure values in high-
when speed of pressure and low-pressure sides.
rotation is Pressure side hot, intake side cold.
changed.
No bubbles Too much refrigerant

(remove refriger- Pressure side very hot. Abnormally
ant from system). high pressure values in intake and
pressure sides.
Remove refrigerant from the sys-
tem, from the pressure side.
08.1.3.2 Cold and Dry Periods with Minimal use of

Air Conditioner
Start the air-conditioner and allow the compressor to op-
erate a few minutes every week to keep the connections,
seals, etc. lubricated. If a low-pressure switch is connect-
ed to the system, it must be bypassed if the ambient tem-
perature is below -1°C. Otherwise the compressor cannot
be started.

6 Equipment
08.1.3.3 Safety Regulations

When working on air-conditioning systems you should re-
member the following precautions:
Always wear goggles, because pressurized refrigerant

may leak out unexpectedly. Hands and other parts of the
skin should also be protected against freezing.
If you get refrigerant on your skin, the affected area

should be flushed with cold water and treated like frost-
bite. If refrigerant gets into your eyes, they should be
flushed with tap water, preferably approx. 15 minutes. If
pain or sight problems occur, seek medical help without
delay.
Refrigerants may never be handled near open fire or live

coals. Toxic gases are formed, if refrigerant and fire get
in touch with each other.
Figure 3. Always wear safety classes and protective

gloves
Figure 4. Do not release refigerant into the air. Use the

recovery unit!

Equipment 7
Figure 5. Keep caps closed!
If an R-134a air conditioner system is mistakenly charged

with R12, serious problems such as compressor seizure
can result.
Figure 6. Don't mix refrigerants!
08.1.3.4 Changing the Components of the Air

Conditioning System
Warning!
According to a resolution on refrigerants it has been
forbidden since July 1, 1989, to release refrigerants
into the atmosphere. Therefore, recovery equipment
should always be used. With such equipment, the
gas can be cleaned and then reused for filling up the
system. This procedure should be followed with all
refrigerants as they are harmful if released into the at-
mosphere.

8 Equipment
When a component is replaced, some of the compressor

oil is removed with it from the system. Top up the system
according to the following table.
Part Oil amount / cm3

Evaporator 60
Condenser 40
Tank 20
Hose (3-8) 10-20
Warning!
Liquid R134-a requires green O-rings. Never use
black O-rings with R134-a.
Figure 7. Green O-ring
Compressor Oil
New compressors are delivered with 1.8 dl of oil in them,
an amount that is sufficient for systems with 1.25 kg of re-
frigerant. For systems up to 1.6 kg of refrigerant, the
amount of oil to be added can be calculated as follows:
Amount of refrigerant in kg x 1.3 + 0.4
Example: 1.5 kg x 1.3 + 0.4 = 2.35 -> add 0.55 dl (2.35-

1.8=0.55)dl
Warning!
Use only synthetic PAG-oil such as ZXL 100 PG or
equivalent in the air conditioning devices.
When the compressor is replaced, measure the amount

of oil in the old compressor. Also drain the new compres-
sor and then fill it through the intake connection, using the
same amount of oil as was drained from the old one.

Equipment 9
Figure 8. Don’t mix oil compressors
08.1.3.5 Troubleshooting
No Cooling
Check:
• uses, electric connections, compressor's earthing,

compressor's electromagnetic clutch, flow controller,
and pressure controller
• drive belt
• compressor
• expansion valve
• temperature regulator valve
• refrigerant hoses
Poor Cooling Power

Check:
• fan
• drive belt tightness
• that no air gets past evaporator
• that the evaporator and condenser are not clogged
• that the fresh air filter is not dirty and clogged
• that the capillary tube of the expansion valve is

properly fastened to the evaporator outlet pipe
• that the thermostat is not switching off too early

10 Equipment
Uneven Cooling
Check:
• that all electric connections at the control switches,

magnetic clutch, and pressure controller are properly
fastened
• that the expansion valve is not clogged
• that the system is correctly filled
• that the thermostat is not faulty
Abnormal Noise
Check:
• that the compressor drive belt is correctly tightened
• that the compressor mounting screws are properly

tightened
• that the amount of refrigerant in the system is correct
Abnormal noises of the system often result from incorrect

mounting of components. If, for example, the compressor
is noisy at a certain speed and the noise disappears when
the speed is raised or lowered, it is likely that the fault is
not in the compressor.
All machines have their specific resonance frequency

where vibrations occur. The speed of rotation at which
noise is heard may vary between different machines.
Often these vibrations can be eliminated by increasing or

decreasing the tightness of the drive belt, or by replacing
it with a belt of different length. Too much tightness caus-
es faster wear of the compressor bearings, the drive belt,
and the pulleys. Therefore, the drive belt should not be
adjusted too tight.
The compressor need not be replaced if the drive belt

'jumps' and causes unusual noise. In such cases, it is ad-
visable to try adjusting the belt tightness or change a belt
of different length. Also a compressor pressure hose of
different length may reduce noise.

Equipment 11
Figure 9. Abnormal Noise
The pressure differences between the intake and output

sides also affect the noise level. A compressor with a low
intake pressure causes more noise than one with a high
intake pressure. Similarly, a compressor with a high out-
put pressure causes more noise as it strains the bearings,
etc.
You should also check that the system is correctly filled

with refrigerant, and that the expansion valve works prop-
erly. Make also sure that the air flow through the evapo-
rator is sufficient.
Also check that the condenser is clean and the air flow
sufficient, and that the system is not too full with refriger-
ant.
As the compressor has many moving parts, all noise can-

not be removed. For instance, the compressor's pistons
generate noise and vibrations of relatively high frequen-
cy.

12 Equipment
08.2 Automatic Central Lubrication

08.2.1 General
This machine is equipped with a central lubrication sys-
tem, which lubricates the most important lubrication
points on a regular basis. See Central Lubrication Dia-
gram.
Figure 10. Automatic Central Lubrication Machine
See detailed operating instructions in the attached P203

Operating instructions.
08.2.2 Indicator Lights and Switch in the

Instrument Panels
H200 H202
S200
Figure 11. Instrument Panel
H200 Lubrication system indicator light, green (light is ON when

lube pump is working)
H202 Warning light, red
S200 Central lubrication switch / Extra lube interval / Reset after
warning

Equipment 13
08.2.2.1 Filling the Tank

Progressive system is designed to feed so-called base
greases until classification NLGI 2. You must take into ac-
count pumping ability of the grease in very low tempera-
tures. When you change the grease quality or brand,
remember that different types of grease may react to
each other.
Figure 12. Filling the Tank
Fill the tank through a filling nipple, which is equipped with

a filter, with a pneumatically or manually operated pump.

14 Equipment
08.2.3 Central Lubrication Diagram K5698190
2 1 0.08ccm/min
4
0.16ccm/min 6 5
3 0.17ccm/min
2 1
6 4 3
5
3
8 7
10 9
12 11
0.08ccm/min
5
0.08ccm/min 2 1
0.17ccm/min 4
6
3
5
2 1 4
0.13ccm/min 4 3
0.25ccm/min 6 5
8 7
0.17ccm/min
2 1
4 3
6 5
0.33ccm/min 2 1
4 3
7 6
8 7
5
0.5ccm/min 1.0ccm/min lubricant

distri- cycle/
quantity
butor pause
2 g/h
4.0ccm/min
0.33ccm/min
2 1
bypass
4 3
6 5
4.0ccm/min
8 2.0ccm/min
1
Figure 13. Central Lubrication Diagram

Equipment 15
1 Luprication pump
2 Distributor
3 Distributor, steering axle, right
3:1 King pin, upper cap
3:2 Cylinder eye
3:3 Pivot axle, rear end
3:4 Cylinder lever
3:6 King pin, lower end
4 Distributor, steering axle, left
4:1 Cylinder eye
4:2 King pin, upper cap
4:3 Cylinder lever
4:4 Pivot axle, front end
4:5 King pin, lower end
5 Distributor, boom end
5:1,2 Joint pin for turning device
5:5.6 Turning device
5:7.8 Turning device
5:9,10 Longitudinal cylinder, upper end
5:11,12 Longitudinal cylinder, lower end
6 Distributor, boom
6:1,2 Side slide pads
6:3,4 Side slide pads
6:5,6 Lower slide pads
7 Distributor, boom
7:1,2 Hoist cylinder, lower end
7:3,4 Boom end
8 Distributor, jacks (optional)
8:1,2 Lower bearing
8:3,4 Cylinder, lower end
8:5,6 Cylinder, upper end

16 Equipment
08.2.4 Central Lubrication Diagram, Toplift
3 6
7
3S1221450
Figure 14. Central Lubrication Diagram

Equipment 17
1 Main distributor, toplift

2 Side distributor, shafts
2:1,2 Shaft cylinder
2:3,4 Rotating lever
2:5,6 Bearing housing
2:7,8 Steering piece
3 Side distributor, shafts
3:1,2 Shaft cylinderi
3:3,4 Rotating lever
3:5,6 Bearing housing
3:7,8 Steering piece
4 Side distributor, toplift
4:1,3 Rotating bearing
4:2 Upper head of pitching cylinder
4:4 Upper head of pitching cylinder
4:5,7 Rotating bearing
4:6 Bottom head of pitching cylinder
4:8 Bottom head of pitching cylinder
4:9 Suspension pin, left
4:10 Suspension pin, right
6 Side distributor,
6:1,3 Side shift cylinder
6:5,7 Length adjustment cylinder
7 Side distributor,
7:1,2 Support bearing for side shift wagon
7:3,5 Side shift cylinder
7:4,6 Support bearing for side shift wagon

APPENDIXES
1. Warranty information
2. Environmental issues
3. Hydraulic diagram
4. Electrical diagram
5. Lifting boom assembly: KG6027/1--5
6. Engine manual
7. Transmission manual
MANAGEMENT OF
PRODUCT
ENVIRONMENTAL ISSUES
2
Contents
1.1 KALMAR ENVIRONMENTAL POLICY ........................................................................................................ 3
1.2 PRODUCT-SPECIFIC ENVIRONMENTAL CONSIDERATIONS ................................................................ 3
1.2.1 Effects of exhaust gases on health and the environment............................................................................. 3
1.2.2 Use of materials.......................................................................................................................................... 4
1.2.3 Energy consumption ................................................................................................................................... 4
1.2.4 Emissions into water and soil ..................................................................................................................... 4
1.2.5 Environmental problems............................................................................................................................. 4
1.2.6 Occupational health and safety .................................................................................................................. 4
1.2.7 Use of products........................................................................................................................................... 4
1.2.8 Complete overhaul or disposal................................................................................................................... 5
1.2.9 Preventive actions....................................................................................................................................... 5
1.3 RECOGNISING ENVIRONMENTAL ISSUES ............................................................................................... 5
1.3.1 Enhancing your environmental awareness................................................................................................. 5
1.3.2 Laws and regulations.................................................................................................................................. 5
1.4 RECYCLING ..................................................................................................................................................... 6
1.4.1 General ....................................................................................................................................................... 6
1.4.2 Sorting ........................................................................................................................................................ 6
1.5 REMEMBER THESE ........................................................................................................................................ 6
3
1.1 KALMAR ENVIRONMENTAL POLICY
ENVIRONMENTAL POLICY
The management of environmental issues at Kalmar Industries Oy Ab’s Tampere factory is based on Kalmar
Industries AB's operational policy, to which this environmental policy is a supplement.
Our operations are based on making continual improvements to prevent pollution of the environment, and on
developing environmentally friendly products and services.
The operations of the factory are developed in accordance with the principles of sustainable development.
Each year, the factory management looks at the main environmental concerns, determines its environmental
objectives and develops an environmental management programme to meet the objectives.
The management will keep track of the environmental objectives and corrective actions by conducting
internal audits as part of the operations system.
Reacting to possible environmental abnormalities and taking the necessary corrective actions is the
responsibility of the entire staff.
Kalmar Industries Oy Ab’s Tampere factory adheres to the current legislation and regulations in its
operations.
Our operations comply with the international environmental system standard ISO 14001 and the principles of
sustainable development set by the International Chamber of Commerce.
1.2 PRODUCT-SPECIFIC ENVIRONMENTAL CONSIDERATIONS
1.2.1 Effects of exhaust gases on health and the environment

Diesel engine emissions are the cause of both health and environmental problems. The most serious
environmental problem is soil acidification, which is manifested in problems in tree growth and plant
formation as well as eutrophication.
Of the diesel engine emissions, nitrous oxide (Nox) will form nitric acid when coming into contact with water,
and sulphur dioxide will form sulphuric acid. Both of these are strong acids that have an effect on plant
formation by decreasing the ability of roots to absorb water and minerals.
Particles are primarily the result of poor combustion of the fuel-air mixture in the diesel engine. They consist
of small carbon particles (<10 µm) on which toxic hydrocarbons have concentrated. These come from the
fuel and lubricating oil. The particles are released into the air along with the exhaust gases and the
mutagenic and carcinogenic hydrocarbons may then enter human lungs.
Emissions Maximum allowable exhaust emissions [g/kWh]
EU level 1 (1999) EPA level 1 (1996) EPA level 2 (1.1.2001)

Power range: 225–450 kW
NOx 9.2 9.2 --

CO 5.0 11.5 3.5
HC 1.3 1.3 --
NMHC + NOx 6.4
PM 0.54 0.54 0.2
4
Hazardous emissions are mainly the result of incorrect adjustment of the motor and lack of maintenance. For
this reason, it is essential that adjustments and maintenance are as described in the instruction manuals.
1.2.2 Use of materials

Reasonable and appropriate use of materials can yield surprisingly high savings in costs and also decrease
environmental load. Preventive maintenance has a decisive influence on decreasing machine downtime.
User and maintenance manuals are intended to teach how to use the machine correctly and safely. Always
use spare parts recommended by the manufacturer, and perform maintenance and repairs in accordance
with the instructions. Follow all fluid changing intervals. Use environmentally friendly materials when
possible. Also try and use recycled materials. In this way, you will achieve the best possible results both for
the environment and safety.
1.2.3 Energy consumption

When using a machine, energy consumption is most influenced by the condition of the machine and the
machine operator’s skills. The manufacturer has installed and set the adjustable values of your machine to
the optimal level for both consumption and emissions. Regular maintenance and immediate repair work
when necessary are a prerequisite for optimal machine operation. Pay special attention to starting the
machine from cold and the instructions given for this.
1.2.4 Emissions into water and soil

The main consideration for the environment is to prevent oil and other toxic liquids from entering ground
water and surface water courses. Even small oil spills can cause significant damage to water courses. Pay
attention to any possible spills on your machine. Make sure the hoses are in good condition to prevent
unpleasant surprises.
When there is a spillage, absorb the spilled oil in sawdust, for example, and remove the contaminated
sawdust according to your site instructions. In case of an accident, immediately contact your supervisor or
the person responsible for environmental issues.
1.2.5 Environmental problems

By environmental problems, we mean faults detected in machine operation that will or might be harmful to
the environment. The most common of these are oil and other liquid spills, toxic waste, leaks and fires. If
seals on cabs are damaged or worn, this can also lead to an environmental problem, in case it causes the
operator to be exposed to noise levels which are too high. If there are possible environmental problems,
immediately contact your supervisor or the person responsible for environmental issues.
1.2.6 Occupational health and safety

Pay attention to your working environment. Perform the necessary maintenance and repair work to prevent
sickness or accidents caused by vibration, noise or other factors. Recognise the needs for safety training,
and get to know the safety bulletins of the hazardous substances you have to work with.
1.2.7 Use of products

Get to know the user and maintenance manuals of your machine well. Find out. For example, which
detergents to use for cleaning the machine. Follow the maintenance and adjustment schedules carefully.
Use the designated oils and other liquids. Check that the oil levels are correct. In general, when using the
machine, make sure that it works properly and is in the appropriate condition for the job.
5
1.2.8 Complete overhaul or disposal

As the lifetime of the machine draws to a close, there are two options for dealing with the machine: complete
overhaul or disposal. If complete overhaul is selected, use the manufacturer's expertise to determine the
amount of repairs needed. This also ensures that any new environmental and safety requirements will be
taken into account. In the case of complete overhaul, the product needs to be equipped to meet the new
requirements. This is the responsibility of the person conducting the repair work.
Environmental load can be reduced by sorting materials and components. Please note that the machine
mostly consists of various iron structures, which are mainly recyclable.
As to the disposal of toxic waste, you must find out the appropriate methods of disposing of the liquids,
materials and components. The safety bulletins of the various liquids and materials contain instructions for
disposal. You can also consult the suppliers of components and the product manufacturer for disposal and
sorting.
1.2.9 Preventive actions

Continuous monitoring of the machine operation along with preventive maintenance and repairs ensures the
safe and uninterrupted use of the product. Follow the maintenance instructions diligently so as not to
jeopardise the machine and its user. By blocking up leaks and checking the joints and pipe installations, you
can ensure that no unwanted liquids are released from the machine.
1.3 RECOGNISING ENVIRONMENTAL ISSUES

It is the responsibility of the employer to train the employees so that they can recognise environmental and
safety issues in their tasks. It is necessary to make sure that the training has been successful and sufficient
information has been provided.
1.3.1 Enhancing your environmental awareness

Aim to define your own environmental awareness. Ask your supervisor for more training if required. After the
training, make sure that you can adapt the information received to your everyday tasks. Product manuals
also contain environmental information about the product.
Ensure that you have sufficient general knowledge about the matters that have to do with your tasks. You
can improve your product knowledge by studying user manuals and spare parts lists provided by the
manufacturer. The manufacturer will also provide the necessary user training when needed. Find out about
the environmental and safety instructions for using, servicing and repairing the machine. What is most
important is to know how to act in exceptional cases.
Try to decrease emissions and the amount of waste produced as best you can. Do not take any risks, work
with care. Try to do the right things in the right way.
1.3.2 Laws and regulations

There are several laws and regulations that have to do with using the machine. It is the employer’s
responsibility to make sure the requirements are met in the work. Environmental issues have become
increasingly important. It is important to be aware of the current requirements, but it is equally important to
follow up on the changes in the requirements. The requirements tend to become tighter all the time.
6
1.4 RECYCLING
1.4.1 General
The primary goal of environmental protection is to decrease the amount of waste produced. If waste is
produced, you must try to utilise it as a material or source of energy. Appropriate and safe processing must
be arranged for all kinds of waste. The sorting of the waste created in our operations is influenced by the
legislation, environmental factors and general tidiness, among other things. The amount of waste driven to
the landfill can be decreased by sorting the waste in the appropriate, labelled receptacles. The most effective
way of protecting the environment is to save material and energy and use environmentally friendly methods
and products.
Become familiar with the waste disposal and recycling instructions of your unit.
1.4.2 Sorting
Metal waste can be collected, sorted and delivered to the industry for use as a raw material and alloying
element. Recycling saves approximately half of the energy that would be consumed if the same amount of
metal were obtained from a mine.
When recovering oil, light oil waste is separated from black oil into a separate receptacle. Used oil of good
quality can be recycled. Take special care when handling oils, as even the smallest amount of oil can cause
extensive damage to the environment and ground water courses. Collect all oil filters and other oily waste,
such as rags, hydraulic hoses, absorbents (sawdust etc.) in the appropriate, labelled receptacles.
Toxic waste means waste that can be hazardous to health or the environment because of some chemical or
other property. When collecting and handling toxic waste, these health and environmental risks need to be
taken into account. Toxic waste typically includes batteries and accumulators, paints, solvents, other special
liquids, fuel waste, coolant waste, aerosols and used fluorescent tubes. Sort all toxic waste and make sure it
is treated appropriately.
1.5 REMEMBER THESE

Being tidy and systematic is the most important consideration.
Remember to:
- Act according to instructions
- Check that all liquids are filled correctly
- Check for leaks
- Make sure that everything is functioning correctly
- Return the tools used for maintenance and repair work to their right place
- Store unused components appropriately
- Recognise environmental problems
- Sort the waste that is produced
- Clear up the environment after finishing work
- Keep the working areas, emergency exits and electric cabinets clear and unobstructed
- Report all abnormal events
- Contact your supervisor or the person responsible for environmental issues if necessary.
Keeping your own working environment tidy and in good order is your personal
responsibility. Tidiness and orderliness influence how the workplace functions, decrease
the number of accidents at work, and contribute to the positive image of the company and
its employees.
Hydraulic schemas T561200T91
A48503.0100 Hydr. schema base machine

K5687770 Hydr.schema, Cabin transfer
A50094.0100 Hydr. schema brakes
K5691600 Hydr. instruction, Twistlock
K5692320 Hydr. instruction, Side shift
K5692370 Hydr. instruction, Tilt
1
K5698240
Hydr. schema for basic machine
1 Steering
2 Lift
3 Boom telescope
4 Spreader turning
5 Tilt
6 Lift cylinder safety valve
7 Boom telescopecylinder safety valve
8 Turning pressure shockvalve
9 Turning directional control valve
10 Directional control valve for active tilt
11 Lockvalve for tilt
12 Speed restrictor for tilt
13 Shuttle valve
14 Brake for turning
15 Return filter
16 Pump for steering, lifting and telescoping
17 Pump for lifting, telescoping and spreader
18 Oilcooler
19 Pressure switch
20 Check valve
21 Relief valve for tilt
22 Check valve
23 Steering unit
24 Indicator for return filter
25 Check valve
26 2/2 solenoid valve, normaly closed
27 Priority valve
28 Check valve
31 Pressure reducing valve
32 Pressure relief and free flow valve for spreader
33 Shuttle valve
35 Check valve
N:o 4K5687770 B Tila: APP Nimitys: HYDR.SCHEMA
Tulostettu 16.01.2001 13:20:31

K5687770
Hydraulic schema
Cabin transfer
1 Cabin transfer hydraulic cylinder

2 Lock valve for cabin motion
4 Pump unit
K5692470
Hydraulic Diagram
Brakes
1 Brakes for driving axle

2 Parking brake
3 Parking brake control valve
4 Accumulators charging valve
5 Pressure filter
7 Pressure switch for brake lights
9 Hydraulic pump
10 Pressure switch for low brake pressure
11 Brake valve for drive axle brakes
14 Check valve
15 Restrictor
16 Indicator for filter
17 Oil cooler
18 Termo bypass
19 Check valve
N:o 4K5691600 Tila: APP Nimitys: Säätöohje Karojen lukitus
Tulostettu 24.01.2001 09:08:23

_PRELIMINARY N:o 4K5692320 Tila: DR Nimitys: Hydr.säätöohje sivusiirto
Tulostettu 24.01.2001 09:06:56

N:o 4K5692370 Tila: APP Nimitys: Hydr.säätöohje pitkittäiskallistus
Tulostettu 21.02.2001 13:18:56

Instructions manual
Appendixes
Electrical diagram K52433.50A Cummins

Art no. Sheet Edition
K52431.00 A Module A81
K52431.40 10 A Battery circuit
K52431.50 11 A Fuse diagram Cummins QSM11
K52431.60 12 A Engine start/stop Cummins QSM11
K52431.70 13 A Alarm lamp indicator
K52431.80 14 A Gauges
K52431.90 15 A Lights
K52431.91 15 A Flasher red lights (optional)
K52432.00 16 A Working lights
K52432.10 17 A Intermittent windscreen wipers and washer
A49448.0100 17 Windows wipers and washer
K52432.20 18 A Transmission control, Mini steering wheel
K52432.30 19 A Oil cooling
K52432.40 20 Transmission operating chart
K52432.50 21 A Air-conditioner
K52432.60 22 A Cabin transferring
K52432.70 23 A Proport control joystick
K52432.80 24 A Spreader movement
K52432.90 25 A Stability control
K52433.00 26 A Lubrication system
K52433.40 27 A Control handle
K52433.10 28 A By-pass switches
K52433.20 29 A Twist locks
K52433.30 30 A Can-bus Cummins
K52410.70 Download loader
K52410.80 Download programs
Model 36000
Powershift Transmission
3-4-6 Speed
Short Drop
Owner Manual
Technical Description
2.6A-20002-C00
Printed Circuit Board for Pump 203

236-13891-1 Models V10 - V13*
236-13891-2 Models V20 - V23*
with Adjustable Pause and Operating Times

Applications for Commercial Vehicles or Industrial Applications
Subject to change without notice
*See page 4 Applications

10051327a
LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259
Owner Manual
2.6A-20002-C00
Survey
Pump Voltage [V] Control unit Setting ranges Part no. Applications
P1: 4 to 60 minutes
12/24 P2: 1 hour to 15 hours
203 integrated A 1: 8 seconds to 120
V10-V13*,** seconds 236-13891-1
V20-V23*,** A 2: 2 to 30 minutes 236-13891-2
integrated P : 4 to 60 minutes
M00-M23*** P : 1 to 15 hours 236-13870-1
Ü : 5 or 30 minutes
without control
unit or with
external control
unit*
12/24
203 integrated
V10-V13*,** ADR 236-13891-1
12/24
203 integrated B : 6 hours, fixed 236-13857-1
H* A: 2 to 30 minutes
12/24
203 integrated B : 6 hours, fixed 236-13857-1
H * ADR A : 2 to 30 minutes
24 VDC external P : 0.5, 1, 2...to 12 hrs 236-13834-1

203 PSG 01 A : 2, 4, 8, 16, 32 min 664-36875-1
24 VDC, 115 VAC,

203 230 VAC external P : 1 min to 160 hrs 236-13860-2
PSG 02 A : 1 min to 160 min
A - Operating time ranges B - Time of availability P - Pause time range Ü - Monitoring time
* 1A1 - Version - Pump without connection for the illuminated pushbutton

**2A1 - Version - Pump with connection for the illuminated pushbutton
***2A4 - Version - Pump with microprocessor control
Note: The applications of the progressive systems are various. There is therefore a corresponding control unit available for each
individual application.
Page 2 from 16
Owner Manual
2.6A-20002-C00
Table of Contents
Page Page
Survey ............................................................................. 2 Repair .............................................................................. 9

Printed circuit board V10-V13 and V20-V23 ............. 4 Operational test/To trigger an additional lubrication ..... 9
Applications ..................................................................... 4 Troubleshooting .......................................................... 10
Mode of operation ........................................................... 4 Technical data ............................................................... 11
Pause time ................................................................ 6 Connection diagram - Industrial applications .............. 12
Operating time .......................................................... 6 Connection diagram - Appplications for
Time storage when the power supply commercial vehicles ...................................................... 13
is switched off ............................................................. 6 Connection diagram - Appplications for
Time setting ...................................................................... 7 commercial vehicles ...................................................... 14
Combinations of the jumper positions .................... 15
Further information can be found in the following manu-

als:
Technical Description Pump Model 203

Technical Description Progressive Metering Devices for Grea-
se and Oil, model SSV
Technical Description for Electronic Control Units of the 203
pump
Printed Circuit Board 236-13857-1 - Model H
Printed Circuit Board 236-13870-1 - Models M 00 - M 15
Printed Circuit Board 236-13870-1 - Models M 16 - M 23
Timer 236-13860-2 Model PSG 02
Installation Instructions
Parts Catalog
Page 3 from 16
Owner Manual
2.6A-20002-C00
Printed Circuit Board V10-V13 and V20-V23

Applications
The printed circuit boards can be used for the following
applications
1.) Lubrication cycles only as a function of the machine wor-

king hours.
When the machine contact (external contact) is switched on

the centralized lubrication system is ready for operation.
Caution: On the PCB 236-13891-1 (V10-V13)* do not con-

nect the red core of the connecting cable to connection 1,
Fig. 1, 14, 16 (terminal 30) since terminal 30 is connected
internally with terminal 15.
1191c95
Fig. 1 - Machine contact, printed circuit board 236-13891-1 (V10-V13)
Note: The PCBs 236-13891-1 and 236-13891-2 differ only

as regards their connection of the terminals. In the case of
PCB 236-13891-2 the terminals 30 and 15 are not connec-
ted.
1191d95
Fig. 2 - Machine contact, printed circuit board 236-13891-2 (V20-V23)
2.) Lubrication cycles only as a function of the running hours

of the commercial vehicle.
When the driving switch (terminal 15) is switched on, the cen-
tralized lubrication system is ready for operation
Note: In the case of PCB 236-13891-2 also connect the

battery voltage (terminal 30).
1060a95
Fig. 3 - Driving switch

*
This designation shows the version of the PCB installed in the pump. It forms part of the pump designation on the name-
plate on each pump.
In the case of P 203-...-.K.-.A. ...-V10 the PCB 236-13891-1 is installed, see connection diagrams 1, 14 and 16.
In the case of P 203 - ... - .K. - .A.. ..-V20 the PCB 236-13891-2 see connection diagram 2, 17.
Page 4 from 16
Owner Manual
2.6A-20002-C00
Mode of Operation
The printed circuit board is integrated in the pump hou-
sing.
00002616
Fig. 4 - Printed circuit board installed in the housing
The printed circuit board automatically controls the sequence

of the pause and operating times of the model 203 central
lubrication pump as a function of the vehicle or machine wor-
king hours tB (Fig. 5).
The sequence of the pause and operating times is activated
when the machine contact or driving switch is switched on.
20002443b
Fig. 5 - Printed circuit board 236-13891-1
A lubrication cycle consists of one pause time and one ope-

rating time. Once the pause time has elapsed, the operating
time starts to run. This lubrication cycle is repeated perma-
nently after the machine or vehicle has been put into opera-
tion. Refer to Fig. 5.
During the operating time the pump element dispenses the
lubricant to the lubrication points via progressive metering
devices.
1059a95
Fig.6 - Time sequence diagram
tB - Working hours T - Lubrication cycle

tP - Various pause times T1 -Stored pause times
T2 -Operating times
Page 5 from 16
Owner Manual
2.6A-20002-C00
The pause time The operating time
- determines the frequency of the lubrication cycles within a - depends on the systems lubricant requirement ;
working cycle; - is adjustable;
- is started and stopped via the machine contact or driving - is finished when the machine contact or the driving switch is
switch; switched off.
- is adjustable. The longer the operating time, the greater the lubricant re-
When the machine contact or the driving switch is switched quirement and vice-versa.
off, the pause times which have already elapsed are stored When the machine contact or the driving switch is switched
and added up (refer to T1, Fig. 6) until the time which has off, the operating times which have already elapsed are
been set on the blue rotary switch (Fig.8) is reached. stored and added up until the time which has been set on the
The pause time setting may be different for each application. red rotary switch (Fig. 10) is reached. After this, the lubricati-
It must be adjusted in accordance with the respective lubri- on cycle starts again.
cation cycles. Also see To set the pause time. The operating time setting may be different for each applica-
tion. It must be adjusted in accordance with the respective
lubricant requirement. Also see To set the operating time.
Time storage
When switching off the ignition voltage and/or the opera-

ting voltage the times already expired are saved for an un-
limited duration.
When the power supply is switched on again the printed cir-
cuit board continues to operate from the point where it had
been interrupted.
Page 6 from 16
Owner Manual
2.6A-20002-C00
Time Setting
* To set the pause or operating time, remove the cover on the
pump housing.
Note: To reset a jumper (Fig. 9), remove the printed circuit

board.
Important: After having set the pause time or operating time,

screw the cover on the pump housing again
00002617
Fig. 7 - The cover to access the printed circuit board has been removed
To set the pause time
The pause time can be set to 15 different settings by means of

the blue rotary switch.
Time ranges: Minutes or hours

20002451b
Fig. 8 - Rotary switch - Pause time
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Minutes 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60
Hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Note: When the switch is on 0 a fault is shown at the right-

hand LED 3, see page 9.
At the same time the factory-set pause time is accepted.
Factory setting
Rotary switch on : ........................................................... 6 hours

or ................................................................................ 24 minutes
The time ranges can be modified by replugging the jumper

(Fig. 9) on the printed circuit board.
Factory setting of the jumper: see chart page 15. The combi-
20002452a nation number can be learnt from the pump type designation
Fig. 9 - Preselection of the time range
code mentioned on the nameplate of each pump.
Page 7 from 16
Owner Manual
2.6A-20002-C00
To set the operating time
The operating time can be set to 15 different setting by me-

ans of the red rotary switch.
Time ranges: Seconds or minutes
20002453b
Fig. 10 - Rotary switch - Operating time
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Seconds 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120
Minutes 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Note: When the switch is on 0 a fault is shown at the right-

hand LED 3 Fig. 12. At the same time the factory-set opera-
ting time is accepted.
Factory setting
Rotary switch on : ...................................................... 6 minutes

or ............................................................................... 24 seconds
The time ranges can be modified by replugging the jumper

(Fig. 11) on the printed circuit board.
Factory setting of the jumper: see chart page 15. The com-
bination numbers can be learnt from the pump type desi-
gnation code mentioned on the nameplate of each pump.
20002437
Fig. 11 - Preselection of the time range
Fault indication
Rotary switch set at 0 Pushbutton 5 Fig. 12 continuously actuated (short circuit)
When one of the rotary switches 2, 3 Fig. 12 is on the 0 If a short circuit occurs at the pushbutton or is present at
setting a fault is shown at the right-hand LED 3. the external illuminated pushbutton Fig.13 or at the con-
The fault is indicated by 4 flashes of the LED. necting parts a fault is shown at the red LED 3, fig. 12.
The pump motor also runs according the flash frequency. If The fault is indicated by 3 flashes of the LED when the
the warning is ignored the controller automatically adopts voltage supply is switched on.
the factory-set values for the operating or pause time The motor of the pump also runs according to the flash
frequency.
Page 8 from 16
Owner Manual
2.6A-20002-C00
Repair
The defective printed circuit boards should be suitably packed If the printed circuit board must be replaced, a model
and returned to the factory. V 10 (V20) will always be delivered. See chart page 15.
Before installing another printed circuit board, take care that
the setting of the jumper or that of the operating/pause time
is the same as on the old printed circuit board.
Operational Test / To Trigger an Additional

Lubrication Cycle
To check the pump operation it is possible to perform an ope-
rational test.
Pumps model 203 installed on machines
* Switch on the machine contact.
Pumps model 203 installed on commercial vehicles
* Switch on the driving switch
For all pumps

To check whether power is applied to the printed circuit
board, observe whether the LED 1 Fig. 12 is lit.
20002457b * Press pushbutton 5 on the printed circuit board (> 2 secon-
Fig. 12 - LED on the printed circuit board ds) until the right-hand LED 3 lights up.
1 - LED, left-hand 4 - Rotary switch, operating time
2 - Rotary switch, pause time 5 - Pushbutton for additional A shorter pause time elapses, followed by a normal lubricati-
3 - LED, right-hand lubrication on cycle.
Additional lubrication cycles can be triggered at any time.
Note: In the case of model 203 pump, version 2A1, with exter-
nal illuminated pushbutton, it is also possible to trigger an addi-
tional lubrication cycle via this pushbutton.
20002458
Fig. 13 - To trigger an additional lubrication cycle, only pumps with illuminated

pushbutton
Page 9 from 16
Owner Manual
2.6A-20002-C00
Troubleshooting
Note: The pump operation can be checked from the outside by circuit board are lit or whehter the signal lamp of the illumi-
observing whether the stirring paddle is rotating (e.g. by trigge- nated pushbutton (if any) is lit.
ring an additional lubrication), whether the LED on the printed
Fault: the pump motor does not run

Cause: Remedy:
Voltage supply interrupted Check the voltage supply to the pump. If necessary, elimina-
te the fault.
Voltage supply to the printed-circuit interrupted Check the line leading from the pump plug to the printed cir-
cuit board.
If the voltage is applied, the left-hand LED is lit.
Voltage supply interrupted betweeen the printed circuit board Triggering an additional lubrication cycle
and the motor If the voltage is applied, the right-hand LED is lit.
Printed-circuit board defective Replace the printed circuit board.
Fault: Right-hand LED 3 Fig. 12 flashes

Cause: Remedy:
One of the two rotary switches 2, 4 Fig. 12 is on 0. Set rotary switch to a number or a letter.
Signal: 4 flashes
Short circuit at pushbutton 5 Fig. 12 or, if present, at the illu- Check whether the short circuit is at he PCB or, if present,
minated push button or at their connecting parts at the illuminated pushbutton.
Signal: 3 flashes If necessary, exchange the PCB or the illuminated pushbut-
ton.
.
Page 10 from 16
Owner Manual
2.6A-20002-C00
Technical Data
Rated voltage ............................................................ 12/24V DC Time setting

Operating voltage
12V/ 24V .......................................................... 9V to 30V Pause time, depending on the jumper position:
Residual rippple in relation ............................................... 4; 8; 12; 24 to 60 minutes
with the operating voltage ................... ± 5% acc. to DIN 41755 ......................................................... 1, 2, 3...to 15 hours
Motor output ............................ Transistor 7A/short-circuit proof Operating time, depending on the jumper position
Reverse voltage protection: ............................................ 8; 16; 24;....to 120 seconds
The operating voltage inputs are protected against ................................................... 2, 4, 6,....to 30 minutes
polarity reversal Factory setting
Temperature range .................................. -25°C to 70°C Pause time .......................................................... 6 hours
Lamp current in the case of pump 2A1 ....................... max. 2 A or .................................................................... 24 minutes
Class of protection Operating time ................................................ 6 minutes
Printed circuit board installed in housing .................... IP 6K 9K or .................................................................. 24 seconds
In order to protect the printed circuit board against condensati-

on it has been covered with a protective varnish.
All the printed circuit boards comply with the EMC (Electroma-
gnetic compatibility) guidelines for road vehicles acc. to DIN
40839 T1, 3 and 4
and the EMC guideline 89 / 336 / EWG
Emitted interference acc. to ................. EN 55011 / 03.91 and
........................................................ EN 50081-1 / 01.92
Noise immunity acc. to ............................. EN 50082-2 / 03.95
The type 203 pumps with PCB V10 - V13 (V20 - V23) comply
with the Automotive EMC Directive 95/54/EEC and with the
EC approval mark e1
021016
shown on the nameplate
Page 11 from 16
Owner Manual
2.6A-20002-C00
Connection Diagram - Industrial Applications, Printed Circuit Board 236-13891-1 (V10-V13)
1192c95
Fig. 14 - Connection diagram Quicklub 203 with adjustable pause time

Connection via Hirschmann type-in connectors DIN 43650-A
A- Printed circuit board 1A1 - Pump without illuminated pushbutton G- Cable connector 2*
B- Pump housing 2A1 - Pump with cable connection for H- Line socket 2 (grey)
C- Cable connector 1 illuminated pushbutton* for connection cable, 3-wire*
D- Line socket 1 (black) F - Machine contact I- Pushbutton for additional lubrication
for connection cable, 3-wire J - Signal lamp in the case of low-level
* on request control
Attention! If a pump model 103 CS...E2 is replaced by a pump model P203-...-...-2A1.10, the lamp connection of the
illuminated pushbutton must be changed from minus to plus.
- Low-level control*
31 - Earth N- Level control*
15 - Driving switch Z- Additional lubrication*

M - Motor - Signal lamp*

1009c93
Fig. 15 - Terminals of the printed circuit board
* equipment available on request
Page 12 from 16
Owner Manual
2.6A-20002-C00
Connection Diagram - Applications for Commercial Vehicles

Printed Circuit Board 236-13891-1 (V10-V13)
1155d95

Connection via square type plug DIN 43650-A
A- Printed circuit board 2A1 - Pump with cable connection K- Cable connector 2**
B- Pump housing for illuminated pushbutton** L- Line socket 2 (grey)
C- Cable connector 1 F - Driving switch with connection cable, 3-wire**
D- Line socket 1 (black) G - Fuse 10 A M- Illuminated pushbutton**
with connection cable, 3-wire H - Cable, black O- Signal lamp in the case of low-level
1A1 - Pump without illuminated pushbutton I- Cable, brown control
P- Battery cutoff*
*does not belong to the scope of delivery

**equipment available on request
Caution: Do not connect the red core (not shown: cf. J Fig. 17)
of the 3-core connecting cable to the wire box 1 (D, Fig. 16)
since the PCB is connected internally between 30 and 15.
Page 13 from 16
Owner Manual
2.6A-20002-C00
Connection Diagram - Applications for Commercial Vehicles

Printed Circuit Board 236-13891-2 (USA)
1155e95

Connection via square type plug DIN 43650-A
A- Printed circuit board 2A1 -Pump with cable connection K- Cable connector 2**
B- Pump housing for illuminated pushbutton** L- Line socket 2 (grey)
C- Cable connector 1 F - Driving switch with connection cable, 3-wire**
D- Line socket 1 (black) G - Fuse 10 A M- Illuminated pushbutton**
with connection cable, 3-wire H - Cable, black O- Signal lamp in the case of low-level
1A1 - Pump without illuminated pushbutton I- Cable, brown control
J - Cable, red P- Battery cutoff*
*does not belong to the scope of delivery

**equipment available on request
30 - Battery voltage - Low-level control*
31 - Earth N- Level control*

15 - Driving switch Z- Additional lubrication*
M - Motor - Signal lamp*
1009b93
* equipment available on request
Fig. 18 - Terminals of the printed circuit board 236-13891-2
Page 14 from 16
Owner Manual
2.6A-20002-C00
Combinations of the jumper positions - Survey
Pause time ranges Operating time ranges Jumper positi-

Possibilities of
P I ons
preselection 4 - 60 min 1 - 15 h 8 - 120 s 2 - 30 min See Fig. 8, 10
Combination no.
V 10, V 20
Standard X X
V 11, V 21 X X
V 12, V 22 X X
V 13, V 23 X X
Page 15 from 16
Owner Manual
2.6A-20002-C00
Page 16 from 16

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00 General Information/

UDRS01.01GB 04 Electric System

07 Frame and Shields

00 General Information/Scheduled Maintenace

00.2 Instructions for Initiating into Maintenance Work ......................... 5

00.3 Regulations for Safe Maintenance Work ........................................ 6

00.4 Preparing of the Machine for Maintenance ..................................... 9

00.5 Maintenance Reports ...................................................................... 10

00.6 Lubrication Oil Recommendations ................................................ 11

00.7 Running-In ....................................................................................... 13

00.8 Scheduled Maintenance ................................................................. 15

00.9 Scheduled Maintenance ................................................................. 16

Maintenance Manual DRS 4527-4531 UDRS01.01GB

UDRS01.01GB Maintenance Manual DRS 4527-4531

00.1 General Information

The professional support of our maintenance organiza-

00.1.1 About the Documentation

• Operator's manual DRS 4527-4531 (in cab with

• Maintenance manual DRS 4527-4531

• Spare parts catalogue with machine card

All documentation can be ordered from Kalmar Indus-

00.1.1.1 Ordering of documentation

Always indicate publication number when ordering.

00.1.2 Warranty Agreement

Maintenance Manual DRS 4527-4531 UDRS01.01GB

00.1.3 To the Maintenance Personnel

UDRS01.01GB Maintenance Manual DRS 4527-4531

00.2 Instructions for Initiating into

00.2.1 General Instructions

By careful following of the maintenance schedule speci-

00.2.2 Maintenance and Repair Personnel

The service person refers to a person, who performs the

Maintenance Manual DRS 4527-4531 UDRS01.01GB

00.3 Regulations for Safe Maintenance

00.3.1 General Safety View Points

1. Thoroughly acquaint yourself with the machiner's

UDRS01.01GB Maintenance Manual DRS 4527-4531

00.3.2 Concerning the Maintenance and Repair

Maintenance Manual DRS 4527-4531 UDRS01.01GB

17.Always remember to engage the parking brake before

00.3.3 Preparing for Hazardous Situations

00.3.3.1 Maintenance Reports

See to it that your service reports are perfectly recorded.

UDRS01.01GB Maintenance Manual DRS 4527-4531

00.3.3.3 Reporting of Dangers

The reports recorded must be filed carefully. It is essential

00.4 Preparing of the Machine for

Prior to the service work: Check the reparations made in

00.4.1 Maintenance Enviroment

Maintenance Manual DRS 4527-4531 UDRS01.01GB

00.5 Maintenance Reports

Define and record the safety level of the machine in the

UDRS01.01GB Maintenance Manual DRS 4527-4531

00.6 Lubrication Oil Recommendations

Required oils, greases and fluids

Maintenance Manual DRS 4527-4531 UDRS01.01GB

Required oils, greases and fluids

UDRS01.01GB Maintenance Manual DRS 4527-4531

The engine should not, however be lugged at low speeds

Especially observe during the running-in period that the

During running-in you should also pay special attention to

Running-in of an overhauled engine follows the same

Maintenance Manual DRS 4527-4531 UDRS01.01GB